Komatsu WB93R-5 User Manual

Download

WEAM006000

Operation & Maintenance Manual

WB93R-5

BACKHOE-LOADER

SERIAL NUMBER

WB93R-5 F50003

and up

ATTENTION

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 has been produced by Komatsu Utility S.p.A. in order to supply their customers with all the neces-

sary information 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 behind the seat, where also the ownership documents and the logbook are usually kept (see "3.5.9 TECHNICAL DOCUMENTATION").

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 your Komatsu Dealer.

q The illustrations contained in this manual may represent machine configurations available on request.

The machines are constantly upgraded in order to increase their efficiency and reliability; this manual sums up all the information regarding the state of the art at the moment when the machine is launched on the market. Contact your Komatsu Dealer for updated information.

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 both the hour meter and the maintenance plan frequently.

q Komatsu Dealers have gathered a considerable amount of experience over years of work in close contact with

the users. If more information is needed, do not hesitate to contact your Komatsu Dealer: he always knows how to get the best performance from the machine, he can recommend 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. Komatsu Dealers also provide assistance for the supply of original Komatsu 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 The incorrect use of the machine and inappropriate maintenance operations may cause serious injury

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 injury 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.

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 onto the machine. To allow the operator to use the machine in total safety, precautions and safety plates are described in this manual and applied to the machine in order to supply information regarding situations that involve potential risks and the measures that may be adopted to avoid such situations.

Terminology used in the signs

The following terms are used in the signs to inform the user that there is a situation of potential danger that may cause injury or damage. In this manual and in the plates applied to the machine the following terms are used to indicate potential dangers.

DANGER

q Indicates a situation of imminent danger that, if not avoided, may cause serious injury and even death.

The use of this term must be limited to situations of extreme danger.

WARNING

q Indicates a situation of potential danger that, if not avoided, may cause serious injury and even death.

CAUTION

q Indicates a situation of potential danger that, if not avoided, may cause moderate injury. This term can

also be used as a warning in case of dangerous procedures.

Other terms used in the signs

In addition to those indicated above, the following warning terms are used to recommend the precautions to be taken to protect the machine or to supply useful information.

IMPORTANT

q This term is used to indicate precautions that must be taken in order to avoid actions that may reduce

the life of the machine.

NOTE

q This word is used to indicate a useful piece of information.

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 onto the machine 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 will work in total safety, with no risk of damaging the machine. In case of doubt regarding the safety measures necessary for some procedures, contact Komatsu or your local Dealer.

INFORMATION ON SAFETY

DANGER

q Before starting any maintenance operation, position the machine on firm and level ground, engage the

safety locks of the equipment and of the controls, stop the engine and apply the parking brake.

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 hood is open, unless this is expressly prescribed for certain maintenance operations.

WARNING

q It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be

held liable for any personal injury, or damage to 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 electric welding operation, disconnect the battery and the alternator. (See

"2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR").

WARNING

q Install only authorized additional equipment (See "6.1 AUTHORIZED OPTIONAL EQUIPMENT").

WARNING

q The machine can travel on roads only if equipped with suitable lighting, signalling and safety devices

and if this type of use is authorized by the logbook. Before travelling on roads, make sure that the equipment with which the machine is provided is homologated and that the safety locks are correctly engaged.

DANGER

q It is absolutely forbidden to manoeuvre the machine while standing on the ground.

Each operation must be carried out by the operator correctly seated in the driving position.

INTRODUCTION

1.3 INTRODUCTION

1.3.1 INTENDED USES

The Komatsu BACKHOE LOADERS described in this manual have been designed and constructed to be used mainly with the following functions:

q LOADER

q EXCAVATOR

Through the installation of optional equipment, the machine can also be used for the following applications:

q HANDLING OF MATERIALS (4IN1 BUCKET - PALLET FORKS)

q SNOWPLOUGH (ANGLEDOZER BLADE - SNOWPLOUGH)

q DEMOLITION (HAND HAMMER - HAMMER ON THE BACKHOE)

q DITCH CLEANING AND DIGGING (SPECIAL BUCKETS)

1.3.2 IMPROPER OR UNAUTHORIZED USE

CAUTION

q This paragraph describes some improper or unauthorized uses of the machine; since it is impossible to

predict all possible improper uses, if the machine is going 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 enclosed 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 BACKHOE LOADERS 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 TRANSPORTATION OF PERSONS even if they are in the operator’s cab.

q TRANSPORTATION OF CONTAINERS with fluids, flammable fluids, loose material, without the appropriate

slinging equipment.

q TRANSPORTATION AND LIFTING (EVEN IF IN EXCEPTIONAL CASES) OF EQUIPMENT OR MATERIALS

THAT PROTRUDE FROM THE BUCKET OR ARE NOT SECURED TO THE BUCKET BY MEANS OF ROPES OR CHAINS.

q USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.

q USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES ON ROADS.

q USE OF THE MACHINE FOR LIFTING DAMAGED VEHICLES.

INTRODUCTION

1.3.3 MAIN CHARACTERISTICS

q Simple and easy operation.

q Servo-assisted steering with priority hydraulic system.

q 4-gear mechanical gearshift and transmission with hydraulic converter; reversal controlled by a lever positioned

under the steering wheel.

q Loader control through a single servo lever ensuring also combined movements that can be modulated propor-

tionally and continually.

q Backhoe controls through mechanical levers ensuring also combined movements that can be modulated propor-

tionally and continually. On request, the backhoe can be controlled by means of two servo levers.

q Complete series of instruments visible from the two operating positions (loader or backhoe).

q Separate accelerator controls for the two operating positions.

q Foot brake control.

q Easy maintenance with simplified intervals.

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 an excessive work load at the beginning of its service life, its productivity and functionality will be untimely reduced. Every new machine must be used carefully, paying special attention to the following indications:

q After the start, let the engine 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 250 hours of use, carry out the following operations, in addition to those to be performed every 250

hours:

1 - Change the hydraulic transmission oil and filter.

2 - Change the differential unit oil (front and rear axle).

3 - Change the final reduction gear oil (front and rear axle).

4 - Change the hydraulic circuit oil filter.

SYNTHETIC BIODEGRADABLE OIL TYPE HEES

On machines in which the synthetic biodegradable oil type HEES is used, the following operations are to be performed together with the standard maintenance operations.

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 innner part to make sure that there are no depos-

its. If abundant deposits are observed, find out what may have caused their accumulation before starting the machine.

q The number of operation hours is indicated by the hour meter.

PRODUCT IDENTIFICATION

1.4 PRODUCT IDENTIFICATION

The Komatsu backhoe 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 be indicated to the Dealer when requiring assistance and ordering spare parts.

1.4.1 MACHINE IDENTIFICATION NUMBER (PIN)

The machine identification number "PIN" is stamped on the right side of the frame front.

RKAB2670

1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) (alternatively for some markets)

The Komatsu BACKHOE LOADERS described in this manual are CE marked, in fact they are in full compliance with the EU harmonised standards. The Product Identification Number (PIN) is stamped on the lower part of the plate. The customer must be able to indicate the PIN at any time, that is why it must compulsorily be written in the following table. The plate with the CE marking is applied inside the cab, on the left vertical wall of the frame, at the height of the brake pedals.

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

MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A. 36025 NOVENTA VICENTINA (VI) - ITALY

MODEL

SERIAL N˚

YEAR

TOTAL WEIGHT

ENGINE POWER

Product Identification Number

RKAB2680

37A-98-11820

RKA14970

MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A. 36025 NOVENTA VICENTINA (VI) - ITALY

1.4.3 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)

PRODUCT IDENTIFICATION

TIPO TYPE - MODEL

NUMERO DI OMOLOGAZIONE HOMOLOGATION NUMBER

MASSA TOTALE AMMISSIBILE TOTAL MASS WEIGHT CARICO AMMISSIBILE ASSE ANT. WEIGHT FRONT AXLE

CARICO AMMISSIBILE ASSE POST. WEIGHT REAR AXLE Product Identification Number

- Massa rimorchiabile: non atto

MATRICOLA SERIAL NUMBER

POTENZA MOTORE

MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A. 36025 NOVENTA VIC. (VI) -ITALY

TYPE

HOMOLOGATION NUMBER

TOTAL MASS WEIGHT

WEIGHT FRONT AXLE

WEIGHT REAR AXLE

Product Identification Number

- Towable weight: not suitable

SERIAL NUMBER

ENGINE POWER

MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A. 36025 NOVENTA VIC. (VI) -ITALY

FROM

ANNO

YEAR

RKAB2680

A TO

37A-98-11840

RKA16060

37A-98-11840

PRODUCT IDENTIFICATION

1.4.4 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE

The identification plate (1) is fixed above the engine head and indicates the engine model, total displacement and serial number. The identification plate (2) is fixed to the left side of the engine block, bears the Manufacturer’s mark and contains the following data:

1 - Engine type

2 - Engine family

3 - Serial number

4 - EC Type Approval

5 - EPA

The serial number (3) is also stamped on the right side of the cylinder block, on the upper part of the oil cooling heat exchanger.

RKAB2690

RKAB2700

1.4.5 FRONT AXLE SERIAL NUMBER

The serial number of the front axle is stamped on the plate positioned on the right side of the axle body.

RKAB2710

RKAB2720

1.4.6 REAR AXLE SERIAL NUMBER

The serial number of the rear axle is stamped on the plate positioned on the right side of the axle body.

1.4.7 TRANSMISSION SERIAL NUMBER

The transmission serial number is stamped on the plate postioned on the right side of the transmission case.

PRODUCT IDENTIFICATION

RKAB2730

1.4.8 CAB SERIAL NUMBER

The cab serial number is stamped on the plate postioned on the left side of the rear wall.

RKAB2750

RKAB2740

PRODUCT IDENTIFICATION

1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS

Machine no. Mod.

Product identification number (PIN)

Engine no.

Front axle no.

Rear axle no.

Transmission no.

Cab no.

Dealer:

Address:

Contact person:

NOTES:

Tel.

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 USE .................................................................................. 4

1.3.3 MAIN CHARACTERISTICS...................................................................................................... 5

1.3.4 RUNNING-IN ............................................................................................................................ 5

1.4 PRODUCT IDENTIFICATION ............................................................................................................... 6

1.4.1 MACHINE IDENTIFICATION NUMBER (PIN) ......................................................................... 6

1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER

(PIN) (alternatively for some markets) ..................................................................................... 6

1.4.3 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) .... 7

1.4.4 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE ................................... 8

1.4.5 FRONT AXLE SERIAL NUMBER............................................................................................. 8

1.4.6 REAR AXLE SERIAL NUMBER ............................................................................................... 9

1.4.7 TRANSMISSION SERIAL NUMBER ........................................................................................ 9

1.4.8 CAB SERIAL NUMBER ............................................................................................................ 9

1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS .................................................................... 10

TABLE OF CONTENTS ........................................................................................................................ 11

SAFETY AND ACCIDENT PREVENTION

2.1 SAFETY, NOISE AND VIBRATION PLATES....................................................................................... 20

2.1.1 POSITION OF THE SAFETY PLATES .................................................................................... 20

2.1.2 PICTOGRAMS AND RELEVANT MEANINGS......................................................................... 22

2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB .......................................... 28

2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED ................................................ 29

2.2 GENERAL PRECAUTIONS .................................................................................................................. 30

2.2.1 GENERAL SAFETY RULES .................................................................................................... 30

2.2.2 SAFETY DEVICES AND GUARDS .......................................................................................... 30

2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS ............................................................. 30

2.2.4 UNAUTHORIZED MODIFICATIONS ....................................................................................... 30

2.2.5 LEAVING THE OPERATOR’S SEAT ....................................................................................... 31

2.2.6 GETTING ON AND OFF THE MACHINE................................................................................. 32

2.2.7 CHECKING THE REAR-VIEW MIRRORS .............................................................................. 32

2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL ..................................................................... 33

2.2.9 PREVENTING BURNS ............................................................................................................ 33

2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER .................................................... 34

2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........................................ 34

2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT ........................................................................ 35

2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE ...................................................... 35

2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT ............................................................... 35

2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE................................................. 36

2.3.1 SAFETY ON THE WORK SITE ............................................................................................... 36

2.3.2 FIRE PREVENTION ................................................................................................................ 36

2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB ............................................. 36

2.3.4 ROOM VENTILATION ............................................................................................................. 37

2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD

WIPER BLADES AND THE BULBS ......................................................................................... 37

TABLE OF CONTENTS

2.4 PRECAUTIONS TO BE TAKEN DURING WORK ................................................................................ 38

2.4.1 WHEN STARTING THE ENGINE............................................................................................. 38

2.4.2 RULES FOR TRAVELLING ON ROADS.................................................................................. 38

2.4.3 HAND SIGNALS ....................................................................................................................... 39

2.4.4 CHECKS FOR TRAVELLING IN REVERSE ............................................................................ 44

2.4.5 MOVING THE MACHINE .........................................................................................................44

2.4.6 WORKING ON SLOPES .........................................................................................................45

2.4.7 PREVENTING ELECTROCUTION .......................................................................................... 46

2.4.8 VISIBILITY ................................................................................................................................ 47

2.4.9 WORKING ON ICY OR SNOW-COVERED SURFACES......................................................... 47

2.4.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ......................................... 47

2.4.11 WORKING ON LOOSE GROUND ........................................................................................... 47

2.4.12 PARKING THE MACHINE........................................................................................................ 48

2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES ................................................................. 49

2.5.1 LOADING AND UNLOADING THE MACHINE ........................................................................ 49

2.5.2 TRANSPORT............................................................................................................................ 49

2.6 BATTERY .............................................................................................................................................. 50

2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY ............................................. 50

2.6.2 STARTING WITH BOOSTER CABLES ................................................................................... 50

2.7 PRECAUTIONS FOR EMERGENCY RECOVERY ............................................................................... 51

2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE ................................................................. 52

2.8.1 WARNING PLATES.................................................................................................................. 52

2.8.2 TOOLS ..................................................................................................................................... 52

2.8.3 PERSONNEL............................................................................................................................ 53

2.8.4 EQUIPMENT ........................................................................................................................... 53

2.8.5 WORKING UNDER THE MACHINE ........................................................................................ 53

2.8.6 KEEPING THE MACHINE CLEAN .......................................................................................... 54

2.8.7 USE OF THE ENGINE DURING MAINTENANCE ................................................................... 54

2.8.8 PERIODICAL CHANGE OF THE SAFETY RELATED PARTS................................................ 54

2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION

OR INSPECTION .................................................................................................................... 55

2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP ...................................... 56

2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR........................................................ 56

2.8.12 USING LAMPS ......................................................................................................................... 56

2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR .......................... 57

2.8.14 PRECAUTIONS CONCERNING THE STARTER .................................................................... 57

2.8.15 HANDLING HIGH-PRESSURE PIPES..................................................................................... 58

2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH- PRESSURE SYSTEMS ....... 58

2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES

AND PRESSURES ...................................................................................................................58

2.8.18 HYDRAULIC ACCUMULATOR ................................................................................................ 59

2.8.19 COOLING FAN AND FAN BELT .............................................................................................. 59

2.8.20 WASTE MATERIALS................................................................................................................ 59

2.8.21 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS........................ 60

2.8.22 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES ......................................... 60

2.8.23 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE............ 61

2.8.24 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE

OIL TYPE «HEES»................................................................................................................... 61

TABLE OF CONTENTS

DESCRIPTION AND USE OF THE MACHINE

3.1 SAFETY LOCKS ................................................................................................................................... 64

3.1.1 FRONT LOADER LOCKS ........................................................................................................ 64

3.1.2 BACKHOE LOCKS ................................................................................................................... 66

3.2 GENERAL VIEWS................................................................................................................................. 68

3.2.1 FRONT GENERAL VIEW .........................................................................................................68

3.2.2 BACKHOE GENERAL VIEW.................................................................................................... 69

3.2.3 CAB INSIDE GENERAL VIEW ................................................................................................. 70

3.2.3.1 CAB INSIDE GENERAL VIEW (mechanical backhoe controls).............................. 70

3.2.3.2 CAB INSIDE GENERAL VIEW (backhoe servo controls) ....................................... 71

3.3 INSTRUMENTS AND CONTROLS ....................................................................................................... 72

3.3.1 FRONT INSTRUMENTS ..........................................................................................................72

3.3.2 SIDE INSTRUMENTS .............................................................................................................. 76

3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER .......................................... 84

3.3.4 PUSH BUTTON ON THE GEARSHIFT LEVER....................................................................... 85

3.3.5 CAB SWITCHES AND ELECTRIC ACCESSORIES ................................................................ 86

3.3.6 MACHINE CONTROLS ............................................................................................................ 89

3.3.6.1 MACHINE CONTROLS (version with mechanically-controlled backhoe) .............. 89

3.3.6.2 MACHINE CONTROLS (version with servo-assisted backhoe) ............................. 91

3.3.6.3 ADJUSTING THE CONTROLS .............................................................................. 111

3.4 FUSES AND RELAYS........................................................................................................................... 114

3.4.1 CENTRAL UNIT FUSES – RELAYS AND ENGINE LINE ........................................................ 114

3.4.1.1 FUSES ................................................................................................................... 114

3.4.1.2 RELAYS .................................................................................................................. 116

3.4.2 VENTILATION, HEATING AND AIR CONDITIONING FUSES AND RELAYS ........................ 117

3.4.2.1 FUSES ................................................................................................................... 117

3.4.2.2 RELAYS ................................................................................................................. 117

3.5 GUARDS, CAB AND DRIVER’S SEAT ................................................................................................ 118

3.5.1 ENGINE HOOD ........................................................................................................................ 118

3.5.2 CAB .......................................................................................................................................... 119

3.5.3 VENTILATION AND HEATING ................................................................................................ 122

3.5.4 AIR CONDITIONER (if installed) .............................................................................................. 123

3.5.5 SEAT ........................................................................................................................................ 125

3.5.5.1 SEAT (STANDARD) ............................................................................................... 125

3.5.5.2 SEAT (OPTIONAL) ................................................................................................ 126

3.5.6 SAFETY BELT.......................................................................................................................... 127

3.5.7 FIRE EXTINGUISHER ............................................................................................................ 127

3.5.8 FIRST AID KIT ......................................................................................................................... 127

3.5.9 TECHNICAL DOCUMENTATION ........................................................................................... 127

3.5.10 STORAGE COMPARTMENT .................................................................................................. 128

3.6 USE OF THE MACHINE........................................................................................................................ 129

3.6.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ................................... 129

3.6.1.1 VISUAL CHECKS.................................................................................................... 129

3.6.1.2 OPERATIONAL CHECKS ...................................................................................... 130

3.6.2 STARTING THE ENGINE ........................................................................................................ 131

3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES ................... 131

3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES ................................ 132

3.6.3 WARMING THE ENGINE ......................................................................................................... 133

3.6.4 HEATING THE HYDRAULIC OIL ............................................................................................. 133

3.6.5 HOW TO MOVE THE MACHINE ............................................................................................. 134

3.6.5.1 DIFFERENTIAL LOCKING...................................................................................... 135

3.6.5.2 ENGAGING THE FOUR-WHEEL DRIVE ............................................................... 135

TABLE OF CONTENTS

3.6.5.3 WORKING ON SLOPES ........................................................................................ 136

3.6.5.4 MAXIMUM IMMERSION DEPTH ............................................................................ 137

3.7 PARKING THE MACHINE .................................................................................................................... 138

3.7.1 PARKING ON LEVEL GROUND .............................................................................................. 138

3.7.2 PARKING ON SLOPES............................................................................................................ 139

3.8 STOPPING THE ENGINE ..................................................................................................................... 140

3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES ................................................................. 141

3.9.1 LOADING AND UNLOADING THE MACHINE ......................................................................... 141

3.9.2 TRANSPORT............................................................................................................................ 142

3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON ................................................................... 143

3.10.1 FUEL AND LUBRICANTS ........................................................................................................ 143

3.10.2 COOLANT ................................................................................................................................ 143

3.10.3 BATTERY ................................................................................................................................. 144

3.10.4 OTHER PRECAUTIONS .......................................................................................................... 144

3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK ...................................................... 144

3.11 PRECAUTIONS TO BE TAKEN AT THE END OF THE WINTER........................................................ 145

3.12 USING THE MACHINE AS A LOADER ................................................................................................ 146

3.12.1 BUCKET POSITION INDICATOR ............................................................................................ 146

3.12.2 ORGANIZING THE WORK AREA ............................................................................................ 146

3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL ........................................................ 147

3.12.2.2 LOADING OPERATIONS ON SLOPES.................................................................. 148

3.12.3 CHANGING THE STANDARD FRONT BUCKET ................................................................... 148

3.13 USING THE MACHINE AS AN EXCAVATOR ...................................................................................... 149

3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST

BE CARRIED OUT .................................................................................................................. 149

3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS............................................... 150

3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS ........................................................................ 151

3.13.4 DIGGING METHOD.................................................................................................................. 152

3.13.4.1 CHANGING THE BACKHOE BUCKET................................................................... 153

3.14 LONG PERIODS OF INACTIVITY ........................................................................................................ 154

3.14.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY .................................. 154

3.14.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY..................................... 156

3.14.3 MAINTENANCE DURING A PERIOD OF INACTIVITY ........................................................... 156

3.14.4 RESTARTING THE ENGINE.................................................................................................... 157

3.14.5 AFTER THE PERIOD OF INACTIVITY .................................................................................... 157

3.15 TROUBLESHOOTING .......................................................................................................................... 158

3.15.1 HOW TO REMOVE THE MACHINE......................................................................................... 158

3.15.2 AFTER THE FUEL HAS RUN OUT .......................................................................................... 158

3.15.3 IF THE BATTERY HAS RUN DOWN ....................................................................................... 159

3.15.3.1 STARTING WITH BOOSTER CABLES .................................................................. 160

3.15.4 OTHER TROUBLES................................................................................................................. 161

3.15.4.1 ELECTRICAL CIRCUIT........................................................................................... 161

3.15.4.2 HYDRAULIC SYSTEM ............................................................................................ 161

3.15.4.3 BRAKING SYSTEM ................................................................................................ 162

3.15.4.4 CONVERTER .......................................................................................................... 162

3.15.4.5 ENGINE................................................................................................................... 162

TABLE OF CONTENTS

MAINTENANCE

4.1 GUIDE TO MAINTENANCE .................................................................................................................. 166

4.2 MAINTENANCE NOTES ....................................................................................................................... 168

4.2.1 NOTES REGARDING THE ENGINE ....................................................................................... 168

4.2.1.1 ENGINE OIL............................................................................................................ 168

4.2.1.2 COOLANT ............................................................................................................... 168

4.2.1.3 FUEL ....................................................................................................................... 169

4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM................................................................. 169

4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM.................................................................... 170

4.2.4 NOTES REGARDING LUBRICATION ..................................................................................... 170

4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING.............................. 171

4.3 FUEL, COOLANT AND LUBRICANTS ................................................................................................ 172

4.3.1 LUBRICATION WITH GREASE ............................................................................................... 173

4.3.2 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS “HEES” ........................... 174

4.4 DRIVING TORQUES ............................................................................................................................. 175

4.4.1 STANDARD DRIVING TORQUES FOR SCREWS AND NUTS .............................................. 175

4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS ................................................. 176

4.4.3 STANDARD DRIVING TORQUES FOR HOSES WITH ORFS................................................ 176

4.5 LUBRICATION ...................................................................................................................................... 177

4.5.1 LUBRICATION DIAGRAM........................................................................................................ 177

4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks) ........................................................ 178

4.5.3 LUBRICATION DIAGRAM (front bucket quick couplings) ........................................................ 179

4.5.4 LUBRICATION DIAGRAM (offset device) ................................................................................ 180

4.6 PERIODICAL CHANGE OF THE SAFETY RELATED COMPONENTS.............................................. 181

4.6.1 SAFETY RELATED PARTS ..................................................................................................... 182

4.6.1.1 FUEL SYSTEM ...................................................................................................... 182

4.6.1.2 DELIVERY HYDRAULIC SYSTEM ........................................................................ 183

4.6.1.3 FRONT LOADER HYDRAULIC SYSTEM............................................................... 184

4.6.1.4 BACKHOE HYDRALIC SYSTEM............................................................................ 185

4.6.1.5 OPERATOR’S SAFETY ......................................................................................... 186

4.7 MAINTENANCE PLAN.......................................................................................................................... 187

4.8 MAINTENANCE PROCEDURES .......................................................................................................... 189

4.8.1 WHEN REQUIRED................................................................................................................... 189

4.8.1.a CHECKING, CLEANING OR CHANGING THE ENGINE AIR FILTERS ................ 189

4.8.1.b CHECKING AND CLEANING THE CAB AIR FILTER ............................................ 190

4.8.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER

(only for machines with air conditioner)................................................................... 191

4.8.1.d CHECKING THE DETERGENT LEVEL IN THE WINDSHIELD WASHER

RESERVOIR ........................................................................................................... 191

4.8.1.e CHECKING THE WINDSHIELD WIPER BLADES.................................................. 192

4.8.1.f LUBRICATING THE CAB DOOR HINGES ............................................................. 192

4.8.1.g FUSES AND RELAYS – CHECK AND CHANGE ................................................... 192

4.8.1.h BLEEDING THE BRAKING CIRCUIT ..................................................................... 193

4.8.1.i CHECKING AND ADJUSTING THE FRONT WHEEL TOE-IN .............................. 194

4.8.1.j CHECKING THE BRAKING EFFICIENCY.............................................................. 194

4.8.1.k CHECKING AND ADJUSTING THE PARKING BRAKE......................................... 195

4.8.1.l CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE ............................. 196

4.8.1.m ADJUSTING THE AUTOMATIC RETURN-TO-DIG DEVICE OF THE

FRONT BUCKET (if installed) ................................................................................. 196

4.8.1.n CHECKING AND ADJUSTING THE STABILIZER SLACK .................................... 197

4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER .............. 198

4.8.2.a CHANGING THE HYDRAULIC OIL FILTER ........................................................... 198

TABLE OF CONTENTS

4.8.2.b CHANGING THE HYDRAULIC OIL ........................................................................ 198

4.8.3 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE ................................... 199

4.8.3.a VARIOUS CHECKS ................................................................................................ 199

4.8.3.b CHECKING THE COOLANT LEVEL....................................................................... 199

4.8.3.c CHECKING THE FUEL LEVEL............................................................................... 200

4.8.3.d CHECKING THE ENGINE OIL LEVEL ................................................................... 200

4.8.4 MAINTENANCE EVERY 10 HOURS OF OPERATION ........................................................... 201

4.8.4.a LUBRICATING THE JOINTS .................................................................................. 201

4.8.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION

(Only for machines in which synthetic biodegradable oil type HEES is used) .......................... 203

4.8.6 MAINTENANCE EVERY 50 HOURS OF OPERATION ........................................................... 203

4.8.6.a CHECKING THE HYDRAULIC OIL LEVEL ............................................................ 203

4.8.6.b CHECKING THE FLUID LEVEL IN THE RADIATOR ............................................. 204

4.8.6.c CHECKING THE BRAKING SYSTEM OIL LEVEL ................................................. 204

4.8.6.d LUBRICATING THE PROPELLER SHAFTS .......................................................... 205

4.8.6.e LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING ............ 206

4.8.6.f CHECKING THE TYRE PRESSURE ..................................................................... 206

4.8.6.g DRAINING THE WATER SEPARATOR ................................................................. 207

4.8.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION ...................................... 208

4.8.8 MAINTENANCE EVERY 250 HOURS OF OPERATION ......................................................... 208

4.8.8.a CHECKING THE ALTERNATOR-FAN BELT.......................................................... 208

4.8.8.b CHECKING AND ADJUSTING THE A/C COMPRESSOR BELT TENSION

(only for machines with air conditioner) ................................................................... 209

4.8.8.c CHECKING THE BATTERY ELECTROLYTE LEVEL ............................................ 210

4.8.8.d CHECKING THE FRONT AXLE OIL LEVELS ........................................................ 211

4.8.8.e CHECKING THE REAR AXLE OIL LEVEL ............................................................. 211

4.8.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL ............................... 212

4.8.8.g CHECKING THE WHEEL NUT DRIVING TORQUE............................................... 212

4.8.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION

(Only for machines in which synthetic biodegradable oil type HEES is used) .......................... 213

4.8.10 MAINTENANCE EVERY 500 HOURS OF OPERATION ......................................................... 213

4.8.10.a CHANGING THE ENGINE OIL ............................................................................... 213

4.8.10.b CHANGING THE ENGINE OIL FILTER.................................................................. 214

4.8.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER ........................................... 214

4.8.10.d CHANGING THE FUEL FILTER ............................................................................. 217

4.8.10.e DRAINING THE FUEL TANK .................................................................................. 218

4.8.10.f DRAINING THE HYDRAULIC OIL TANK

(only for machines in which synthetic biodegradable oil type HEES is used) ......... 219

4.8.10.g CLEANING THE OUTSIDE OF THE RADIATOR .................................................. 220

4.8.10.h CLEANING THE OUTSIDE OF THE A/C CONDENSER

(only for machines with air conditioner) .................................................................. 221

4.8.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION ....................................................... 222

4.8.11.a CHANGING THE FRONT AXLE OIL ...................................................................... 222

4.8.11.b CHANGING THE REAR AXLE OIL......................................................................... 223

4.8.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL............................................ 224

4.8.11.d CHANGING THE HYDRAULIC TRANSMISSION OIL FILTER .............................. 225

4.8.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION ....................................................... 226

4.8.12.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER......... 226

4.8.12.b CHANGING THE COOLANT ................................................................................. 228

4.8.12.c CHANGING THE BRAKING SYSTEM OIL ............................................................. 229

4.8.12.d CHECKING THE ALTERNATOR AND THE STARTER ......................................... 230

4.8.12.e CHANGING THE ALTERNATOR BELT.................................................................. 230

4.8.12.f CHECKING THE A/C COOLING GAS QUANTITY

(only for machines with air conditioner) ................................................................... 230

4.8.13 MAINTENANCE EVERY 3000 HOURS OF OPERATION ....................................................... 231

TABLE OF CONTENTS

4.8.13.a CHECKING THE ENGINE RETAINING SCREWS AND DAMPING ELEMENTS .. 231

4.8.13.b CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE AND

THE INJECTION TIMING ADVANCE ..................................................................... 231

4.8.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION ....................................................... 232

4.8.14.a CHANGING THE A/C DEWATERING FILTER

(Only for machines with air conditioner) ................................................................. 232

4.8.14.b CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR

(Only for machines with air conditioner) ................................................................. 232

4.8.14.c CHANGING THE ENGINE THERMOSTATIC VALVE ............................................ 232

TECHNICAL SPECIFICATIONS

5.1 TECHNICAL DATA ............................................................................................................................... 234

5.1.1 STANDARD OVERALL DIMENSIONS .................................................................................... 234

5.1.1.1 OVERALL DIMENSIONS WITH STANDARD ARM ................................................ 234

5.1.1.2 OVERALL DIMENSIONS WITH TELESCOPIC ARM ............................................. 234

5.1.2 TECHNICAL CHARACTERISTICS .......................................................................................... 235

5.1.3 LIFTING CAPACITIES ............................................................................................................. 237

5.1.3.1 SYMBOL TABLE ..................................................................................................... 237

5.1.3.2 LIFTING CAPACITIES (STANDARD ARM) ............................................................ 238

5.1.3.3 LIFTING CAPACITIES (TELESCOPIC ARM) ......................................................... 239

AUTHORIZED OPTIONAL EQUIPMENT

6.1 AUTHORIZED OPTIONAL EQUIPMENT ............................................................................................. 242

6.1.1 PRECAUTIONS REGARDING SAFETY .................................................................................. 242

6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT.................................. 243

6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT........................................................ 244

6.2 FRONT EQUIPMENT QUICK COUPLING DEVICES .......................................................................... 245

6.2.1 MANUAL QUICK COUPLING .................................................................................................. 245

6.2.2 HYDRAULIC QUICK COUPLING FOR STANDARD BUCKET ............................................... 246

6.2.3 HYDRAULIC QUICK COUPLING FOR 4in1 BUCKET AND OPTIONAL EQUIPMENT

WITH UNIDIRECTIONAL OIL FLOW ...................................................................................... 246

6.3 4in1 BUCKET........................................................................................................................................ 247

6.3.1 DESCRIPTION AND CONTROLS .......................................................................................... 247

6.3.2 SAFETY DEVICES .................................................................................................................. 247

6.3.3 INSTALLING THE 4in1 BUCKET ............................................................................................ 248

6.3.4 USING THE 4in1 BUCKET ...................................................................................................... 249

6.3.5 MAINTENANCE ....................................................................................................................... 249

6.4 PALLET FORKS ................................................................................................................................... 250

6.4.1 DESCRIPTION ......................................................................................................................... 250

6.4.2 SAFETY DEVICES .................................................................................................................. 251

6.4.3 USING THE FORKS ................................................................................................................ 251

6.4.3.1 PREPARING THE PALLET FORKS FOR USE ..................................................... 252

6.4.3.2 OVERTURNING THE FORKS FOR TRAVEL ON ROADS ................................... 252

6.4.4 REMOVING THE FORKS ........................................................................................................ 253

6.4.5 INSTALLING THE FORKS ....................................................................................................... 253

6.4.6 MAINTENANCE ....................................................................................................................... 253

6.5 BACKHOE TELESCOPIC ARM............................................................................................................ 254

6.5.1 DESCRIPTION AND CONTROL .............................................................................................. 254

6.5.1.1 CONTROL (version with mechanically-controlled backhoe) .................................. 254

6.5.1.2 CONTROL (version with servo-assisted backhoe).................................................. 254

6.5.2 SAFETY DEVICES ................................................................................................................... 255

6.5.3 USING THE TELESCOPIC ARM ............................................................................................. 255

6.5.4 MAINTENANCE ....................................................................................................................... 256

6.5.4.1 ADJUSTING THE GUIDE SLACK........................................................................... 256

TABLE OF CONTENTS

6.6 CONFIGURATION FOR THE INSTALLATION OF THE DEMOLITION HAMMER ............................. 258

6.6.1 DESCRIPTION AND CONTROL .............................................................................................. 258

6.6.1.1 CONTROL (version with mechanically-controlled backhoe) ................................... 258

6.6.1.2 CONTROL (version with servo-assisted backhoe).................................................. 258

6.6.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED ............................. 259

6.6.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER ............................................... 263

6.6.3.1 INSTALLING THE HAMMER .................................................................................. 263

6.6.3.2 REMOVING THE HAMMER.................................................................................... 265

6.6.4 USING THE HAMMER ............................................................................................................. 265

6.6.5 MAINTENANCE........................................................................................................................ 265

6.7 APPLICATION OF THE OFFSET DEVICE ........................................................................................... 266

6.7.1 DESCRIPTION AND CONTROL ............................................................................................. 266

6.7.1.1 CONTROL (version with mechanically-controlled backhoe) ................................... 266

6.7.1.2 CONTROL (version with servo-assisted backhoe).................................................. 267

6.7.2 MAINTENANCE........................................................................................................................ 267

6.8 CONFIGURATION FOR THE USE OF OPTIONAL EQUIPMENT WITH

UNIDIRECTIONAL OIL FLOW.............................................................................................................. 268

6.8.1 DESCRIPTION AND CONTROL ............................................................................................. 268

6.8.1.1 CONTROL (version with mechanically-controlled backhoe) ................................... 268

6.8.1.2 CONTROL (version with servo-assisted backhoe).................................................. 268

6.8.2 INSTALLING AND CONNECTING THE EQUIPMENT ........................................................... 269

6.8.3 MAINTENANCE........................................................................................................................ 269

6.9 CONFIGURATION FOR THE USE OF THE CLAMSHELL BUCKET .................................................. 270

6.9.1 DESCRIPTION AND CONTROL .............................................................................................. 270

6.9.1.1 CONTROL (version with mechanically-controlled backhoe) ................................... 270

6.9.1.2 CONTROL (version with servo-assisted backhoe).................................................. 271

6.9.2 INSTALLING THE CLAMSHELL BUCKET............................................................................... 272

6.9.3 USING THE CLAMSHELL BUCKET ........................................................................................ 273

6.9.4 MAINTENANCE........................................................................................................................ 273

6.10 CONFIGURATION FOR THE USE OF THE HAND HYDRAULIC HAMMER....................................... 274

6.10.1 DESCRIPTION AND CONTROL .............................................................................................. 274

6.10.2 INSTALLING AND REMOVING THE HAND HAMMER .......................................................... 275

6.10.2.1 CONNECTING THE HAND HAMMER.................................................................... 275

6.10.2.2 REMOVING THE CONNECTIONS ........................................................................ 276

6.10.3 USING THE HAMMER ............................................................................................................. 276

6.10.4 MAINTENANCE........................................................................................................................ 276

6.11 LOAD STABILIZER SYSTEM (LSS) (Optional) .................................................................................. 277

6.11.1 LOAD STABILIZER SYSTEM (LSS) ACCUMULATOR ........................................................... 277

6.12 REAR EQUIPMENT MECHANICAL QUICK COUPLING DEVICE ...................................................... 278

6.12.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE ...................................................... 279

6.12.2 MAINTENANCE........................................................................................................................ 280

SAFETY AND ACCIDENT PREVENTION

SAFETY, NOISE AND VIBRATION PLATES

42N-93-1

1380

42 N

9 3-1 1220

42N-93-1

1360

42N-

93-1

3 95

- 9 3

- 1 1 330

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 piece.

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.

DURANTE I TRASFERIMENTI

SU STRADA I PEDALI FRENO

DEVONO ESSERE COLLEGATI

CON APPOSITO SPINOTTO

PRIMA DI PARTIRE PER IL

TRASFERIMENTO SU

STRADA BLOCCARE LA LEVA

COMANDO PALA!

0 8 3 1 1

3 9

N 2 4

3 9 5

- 9 3

- 1 1 3 3

42N-93-11130

NON INSERIRE LA DOPPIA TRAZIONE

IN TRASFERIMENTO STRADALE

DO NOT ENGAGE 4 WHEEL DRIVE

DURING ROAD TRAVELLING

W˜HREND DER STRASSENFAHRT NICHT

DIE 4 RADANTRIEB EINSCHALTEN

NE PAS ENGAGER LES 4x4 POUR LE

DEPLACEMENT ROUTIER

DESCONECTAR 4x4 ANTES DE CIRCULAR

EN CARRETERA

NˆO ENGRENE A TRASMISSˆO AS 4

RODAS CONDUZINDO EM ESTRADA

42N-93-11120

DURANTE I TRASFERIMENTI SU STRADA I PEDALI FRENO DEVONO ESSERE COLLEGATI CON APPOSITO SPINOTTO

42N-93-11110

PRIMA DI PARTIRE PER IL TRASFERIMENTO SU STRADA BLOCCARE LA LEVA COMANDO PALA!

SPEED CONTROL

BUCKET CLOSE

KICK-DOWN

BUCKET OPEN

DIFFERENTIAL

DECLUTCH

LOCK

4 2 N

9 3

-1 1

2 2 0

g k 0

0 1 L

0 8

3 1 1

- 3 9

- N 2 4

42N-93-1

1360

RKA13480

SAFETY, NOISE AND VIBRATION PLATES

00 kg

RKA13490

42N-93-11310

42N-93-11320

RKAB4740

SAFETY, NOISE AND VIBRATION PLATES

2.1.2 PICTOGRAMS AND RELEVANT MEANINGS

The warning and danger signs applied onto the machine are accompanied by or illustrated through pictograms. The personnel in charge with handling and maintenance operations must know the symbols contained in the pictograms perfectly; the symbols and the relevant meanings are explained in the following list.

WORK AREA

q Do not approach or stand in the equipment operating radius

when the boom and the bucket are lifted.

42N-93-11380

RKA14690

DO NOT OPEN THE ENGINE HOOD

q Do not open or remove the hood when the engine is running.

HYDRAULIC OIL TOPPING UP

q (Only for machines in which synthetic biodegradable oil type

HEES is used)

OVERTURNING THE FORKS

q When overturning the forks for use or storage, be very care-

ful, since hands and feet may be seriously injured or even cut off.

42N-93-11370

RKA14700

BIO-OIL

42N-93-11370

RKA14710

RKA14720

CONSULT THE MANUAL

q Carefully read the contents of the manual before using the

machine or performing maintenance operations.

RISK OF CRUSHING

q Do not touch or stand near moving parts, since your hands

may be crushed or cut off.

SAFETY, NOISE AND VIBRATION PLATES

42N-93-11130

RKA14730

PRECAUTIONS TO BE TAKEN WHEN HANDLING THE GAS SHOCK ABSORBERS

q Do not remove the shock absorber.

q Do not bring the shock absorber near sparks or naked

flames.

q Do not make holes in the shock absorber, do not weld or use

oxyhydrogen flames.

q Do not hit the shock absorber.

DO NOT START THE ENGINE WITH INCORRECT PROCEDURES

q Start the engine and operate the machine only while seated

with fastened safety belt.

q Do not attempt to start the engine by causing a short-circuit

with the terminals of the starter. This may cause serious injury and even death.

42N-93-11220

RKA14740

395-93-11330

RKA14750

42N-93-11350

RKA14760

SAFETY, NOISE AND VIBRATION PLATES

LOCK THE LOADER CONTROL

q When it is necessary to travel on roads, lock the loader con-

trol lever before starting.

CONNECT THE BRAKE PEDALS

q When the machine travels on roads, the brake pedals must

be connected with the apposite pin.

PRIMA DI PARTIRE PER IL

TRASFERIMENTO SU

STRADA BLOCCARE LA LEVA

COMANDO PALA!

42N-93-12460

RKA14770

DURANTE I TRASFERIMENTI SU STRADA I PEDALI FRENO

DEVONO ESSERE COLLEGATI

CON APPOSITO SPINOTTO

42N-93-11110

RKA14780

DO NOT ENGAGE THE 4WD

q When the machine travels on roads, do not engage the

4WD.

HYDRAULIC OIL TOPPING UP

37A-98-12210

42N-93-11120

RKA14790

RKA14800

HYDRAULIC OIL LEVEL

37A-98-12290

RKA14810

HYDRAULIC OIL FILTER

REFUELLING

FUEL FILTER

SAFETY, NOISE AND VIBRATION PLATES

37A-98-12310

RKA14820

37A-98-12240

RKA14830

ENGINE LUBRICATING OIL FILTER

ENGINE AIR SUCTION FILTER

37A-98-12250

37A-98-12230

37A-98-12260

RKA14840

RKA14850

RKA14860

ENGINE COOLANT

37A-98-12340

RKA14870

SAFETY, NOISE AND VIBRATION PLATES

COOLANT PRESSURE

TRANSMISSION OIL LEVEL

TRANSMISSION OIL FILTER

37A-98-12270

395-93-11440

RKA14880

RKA14590

POWER OUTLET

BOOM LOCK

SWING LOCK

395-93-11420

12 V

42N-93-11270

42N-93-11320

RKA14580

RKA14890

RKA14900

42N-93-11310

RKA14910

ANCHORAGE POINT

EMERGENCY EXIT

BRAKE OIL

SAFETY, NOISE AND VIBRATION PLATES

42N-93-11360

RKA14920

42N-93-11260

RKA14930

DO NOT LIFT MORE THAN 1000 kg

SWL 1000 Kg

RKA14950

RKA14940

SAFETY, NOISE AND VIBRATION PLATES

2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB

q The noise 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 noise plate, make sure that this plate is applied also on

the new piece.

ISO 6396

NOISE OUTSIDE THE CAB

q This value indicates the noise level outside the machine and

refers to the noise perceived by persons in the vicinity of the work area.

NOISE INSIDE THE CAB

q This value indicates the maximum noise level perceived by

the operator’s ears inside the cab when this is completely closed.

2000/14/EC

RKAB4750

RWA37720

ISO 6396

RWA37730

SAFETY, NOISE AND VIBRATION PLATES

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.

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 Follow all the safety rules, precautions and instructions when using the machine or performing maintenance op-

erations.

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 signs described above 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 re-

paired if damaged. Do not 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 Any improper use of the safety devices may result in serious injury 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 personal injury or damage. Also avoid wearing clothes that are dirty with oil or fuel, since they catch fire very easily.

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 protection.

q When working for 8 hours with a noise level exceeding 90

dBA, it is necessary to use headphones or ear plugs and be particularly careful, especially towards the end of the work shift.

RWA00960

2.2.4 UNAUTHORIZED MODIFICATIONS

q Any modification made to the machine without the authorization of Komatsu can involve hazards.

q Before making a modification, consult your Komatsu Dealer. Komatsu declines any responsibility for injury or

damage caused by unauthorized modifications.

2.2.5 LEAVING THE OPERATOR’S SEAT

q When leaving the operator’s seat, even if for a short time,

make sure that the machine is in a safe position. (See "2.4.12 PARKING THE MACHINE").

q Before leaving the operator’s seat, carry out the following

operations in the sequence indicated below:

1 - Lower the equipment to the ground.

2 - Press the servo control locking button (LED on).

GENERAL PRECAUTIONS

NOTE

q On machines equipped with backhoe servo controls, all

movements are inhibited when the button is in locking position (LED on).

3 - Engage the safety lock of the mechanical controls.

4 - Apply the parking brake.

5 - Shift the reversing gear lever to the neutral position.

6 - Stop the engine.

If you have to go so far away that you will not be able to see the machine, extract the ignition key.

RKAB2760

RKAB2780

RWA02000

RKAB2800

RKAB4820

GENERAL PRECAUTIONS

2.2.6 GETTING ON AND OFF THE MACHINE

q Do not jump on or off the machine, both when it is at rest and

when it is moving.

q Always use the handles and the safety ladders to get on or

off the machine, and be very careful.

q Do not hold or rest on the steering wheel or the gearshift le-

ver.

q Both when getting on and when getting off the machine, al-

ways maintain three points of contact (holding or resting points), in order to avoid losing your balance and falling down.

q Tighten the handle and ladder connection screws if they are

loose and clean the handles and steps if they are dirty with oil or grease. Carefully clean the cab floor if it is dirty with oil, grease, mud or rubble.

RKAB2820

2.2.7 CHECKING THE REAR-VIEW MIRRORS

q Make sure that the rear-view mirrors are clean and correctly

positioned; they must allow the operator to see the rear of the machine with no need to move the chest with respect to the normal work position.

q If the rear-view mirrors should move or break during work,

stop the machine immediately and fasten or change them.

q Working without checking the area behind the machine is

dangerous, since the machine may hit persons who are incautiously standing in the work area, fixed obstacles or manoeuvring vehicles.

RWA18670

RWA00340

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 flammable and therefore very dangerous.

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 con-

stantly in contact with the filler until you have finished, in order to avoid sparks due to static electricity.

q After topping up, tighten the fuel and oil safety caps securely.

q Do not fill the tank completely, in order to leave room for the

fuel to expand.

q If some fuel is inadvertently 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, loosen the radiator cap slowly, 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 hydraulic circuit oil level,

stop the engine and let the oil cool down. The hot oil that may be sprayed out of the tank may cause serious burns.

RWA00980

RWA00990

GENERAL PRECAUTIONS

2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER

q Asbestos powder can be hazardous to your health if it is in-

haled.

q If you handle materials containing asbestos fibers, keep to

the instructions given below:

1 - Do not use compressed air, but only exhaust fans to

clean the machine, and make sure that the room in which you are working is properly ventilated.

2 - Use low-pressure water to abate dust when cleaning.

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 wet and put in a sealed and marked container, so that it can be safely disposed of according to the regulations in force.

RWA01000

2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT

q Do not stand within the operating radius of the work equip-

ment, 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 articulations

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 arms to be lifted,

if you are not sure that the locks are correctly positioned and connected to the arms.

RWA01010

RWA01020

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 nec-

essary disinfectants, bandages, medicines, etc.

q It is necessary to know what to do in case of fire.

q Make sure that you have the phone numbers of the persons

RWA01030

or structures you may need to contact in case of an emergency at hand (both at the worksite 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 (ROPS/FOPS). Contact 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 a Komatsu Dealer.

Installing and using any equipment not authorized by Komatsu may create safety problems and may have negative consequences on both the efficiency and life of the machine.

q Komatsu cannot be held liable for any injury, accident, product failure resulting from the installation and use of

unauthorized equipment.

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 be-

fore starting the engine define the work plan and the best and safest operating procedure.

q Level the ground surface as much as possible before carry-

ing 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 elec-

trical lines are located under the work site, contact the relevant utility company in order to find out their exact position or to disconnect them until the end of the operations. Be careful not to sever or damage any of these lines.

RWA00220

q Check the water depth and the force and flow direction of the

current before operating in water or on river banks.

2.3.2 FIRE PREVENTION

q Completely 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 excess oil, fuel or other flammable fluids.

q Make sure that fire extinguishers are available in the work

area.

2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB

RWA01040

q Do not leave objects or tools lying around in the operator's cab. They may prevent the use of the brakes and

cause serious accidents.

q Keep the cab floor and the controls (steering wheel 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 available at Komatsu or its Dealers.

q Make always sure that the lock of the right door, which is considered the emergency door, is open.

PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE

2.3.4 ROOM VENTILATION

q Before starting the machine in confined or poorly ventilated

places, provide for proper ventilation or connect the engine exhaust pipe to a suction duct. The engine exhaust gases can be deadly.

RWA01050

2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS

q Remove any trace of dirt from the cab windows and the lights and clean the rear-view mirrors; this will ensure

good visibility on the work area.

q Adjust the rear-view mirrors if they have moved, so that the operator seated in the driving position can clearly

see the area behind the machine. If any window, light or mirror is damaged, change it.

q Make sure that the road lights, stop lights, direction indicators and work lights are properly working. If necessary,

change the faulty bulbs with new ones, making sure that their power is correct.

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 doubt on the efficiency of the scraping wire, change the blades.

PRECAUTIONS TO BE TAKEN DURING WORK

2.4 PRECAUTIONS TO BE TAKEN DURING WORK

2.4.1 WHEN 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 steering wheel or the control levers.

q When starting the engine, sound the horn as an alert signal.

q Start the engine and operate the machine only while seated with fastened safety belt.

q Do not allow anyone to get on the machine or enter the cab.

2.4.2 RULES FOR TRAVELLING ON ROADS

q The machine is equipped with multifunction safety locks that must be used both for maintenance operations and

road travel.

q When it is necessary to travel on roads, proceed as follows:

1 - Position the safety lock of the front loader so that the bucket is lifted from the ground, thus ensuring better vis-

ibility and the stability of the machine.

2 - Install the front bucket swing lock and secure it with the safety pins.

3 - Install the teeth protection casing on the front bucket.

4 - Lift the backhoe boom until engaging the safety coupling.

The arm and bucket must in any case be completely folded.

5 - The backhoe must be rotated and resting against the machine structure.

This is the only position homologated for road travel in Italy.

6 - For travelling with folded backhoe, the unit must be moved on its guide in such a way as to be positioned to-

wards the road centre, against the lock and with the bucket facing the road side.

7 - Fasten the backhoe with the swing lock pin.

8 - Connect the safety chains to prevent the accidental lowering of the stabilizers.

9 - Engage the safety locks of the loader and backhoe control levers.

For further information on their position, see "3.1 SAFETY LOCKS".

q When it is necessary to travel on roads, the four-wheel drive must be disengaged and the brake pedals must be

connected with the appropriate pin.

q When travelling on roads, keep to the rule of the road and operate the flashing light positioned on top of the cab.

q When travelling on roads, keep the work lights off.

IMPORTANT

q In any case, keep to the traffic rules in force.

PRECAUTIONS TO BE TAKEN DURING WORK

2.4.3 HAND SIGNALS

WARNING

q When it is necessary to position loads, make excavations or move the machine with a reduced field of vi-

sion, the operator must be helped by another person (signalman) who should stand on the ground and give signals to indicate the manoeuvres to be carried out according to the specific instructions provided for by the relevant regulations.

q No movement or operation may be carried out if the signals have not been clearly understood by the op-

erator and the signalman.

q When additional instructions different from those defined by the hand signalling system are necessary,

these must be agreed upon by the two operators before starting the job.

q Only one person must be entrusted with giving signals.

q The operator must make sure that the signalman is always within his field of vision and follow all his sig-

nals.

The use of hand signals serves to direct the lifting, handling and positioning of the loads lifted by the work equipment. Hand signals can also be used during digging operations or when the machine travels, if the field of vision of the operator is reduced. The direction of movement of the hands and arms in relation to the machine must define the signal, independently of the position of the signalman. Hand signals must be given following the indications below.

1 - LIFT THE LOAD VERTICALLY

One forearm in vertical position and forefinger pointing upwards: turn the hand making small circles.

2 - LOWER THE LOAD VERTICALLY

One arm down and forefinger pointing downwards: turn the hand making small circles.

RKA15140

RKA15150

PRECAUTIONS TO BE TAKEN DURING WORK

3 - MOVE THE LOAD AWAY IN HORIZONTAL DIRECTION

One arm outstretched and hand in vertical position with the palm facing towards the load to be moved away: move the hand in the direction of the movement to be carried out.

4 - BRING THE LOAD NEARER IN HORIZONTAL DIREC-

TION One arm outstretched and hand in vertical position with the palm facing towards yourself: move the hand in the direction of the movement to be carried out.

5 - LIFT THE BOOM

One arm laterally outstretched in horizontal position and clenched fingers: point the thumb upwards.

RKA15160

RKA15170

6 - LOWER THE BOOM

One arm laterally outstretched in horizontal position and clenched fingers: point the thumb downwards.

7 - SWING THE BOOM

One arm laterally outstretched in horizontal position: point the forefinger towards the desired swing direction.

8 - SWING THE BOOM

One arm laterally outstretched in horizontal position: point the forefinger towards the desired swing direction.

RKA15180

RKA15190

RKA15200

RKA15210

9 - FOLD THE ARM

With both fists clenched, point the thumbs inwards.

10 - EXTEND THE ARM

With both fists clenched, point the thumbs outwards.

11 - FOLD THE BUCKET

Keep one hand still and closed. Rotate the other hand vertically with the forefinger pointing towards the closed hand.

PRECAUTIONS TO BE TAKEN DURING WORK

RKA15220

RKA15230

12 - OPEN THE BUCKET

Keep one hand still and open. Rotate the other hand vertically with the forefinger pointing towards the open hand.

13 - TRAVEL WHILE STEERING

Lift the forearm corresponding to the inner steering side with clenched fist. Rotate the other fist vertically indicating the wheel’s turning direction.

14 - TRAVEL WHILE STEERING

Lift the forearm corresponding to the inner steering side with clenched fist. Rotate the other fist vertically indicating the wheel’s turning direction.

RKA15240

RKA15250

RKA15260

RKA15270

PRECAUTIONS TO BE TAKEN DURING WORK

15 - TRAVEL STRAIGHT AHEAD

Rotate the fists vertically indicating the turning direction of the wheels.

16 - TRAVEL STRAIGHT AHEAD

Rotate the fists vertically indicating the turning direction of the wheels.

17 - DISTANCE TO BE COVERED

Hands raised and palms facing inwards: move the hands laterally indicating the distance to be covered.

RKA15280

RKA15290

18 - CARRY OUT THE MOVEMENTS SLOWLY

One hand still in front of the hand that indicates the movement to be carried out. (The figure represents the “lift slowly” signal).

19 - STOP

One arm outstretched laterally, hand open and palm facing downwards: move the arm forwards and backwards.

20 - EMERGENCY STOP

Both arms outstretched laterally in horizontal position, hands open and palms facing downwards: move both arms forwards and backwards.

RKA15300

RKA15310

RKA15320

RKA15330

21 - STOP THE ENGINE

Pass thumb or forefinger across the throat.

22 - RETRACT THE TELESCOPIC ARM

One forearm lifted forwards and clenched fingers: point the thumb in the direction of the movement to be carried out.

23 - EXTEND THE TELESCOPIC ARM

One forearm lifted forwards and clenched fingers: point the thumb in the direction of the movement to be carried out.

PRECAUTIONS TO BE TAKEN DURING WORK

RKA15340

RKA15350

RKA15360

PRECAUTIONS TO BE TAKEN DURING WORK

2.4.4 CHECKS FOR TRAVELLING IN REVERSE

q When operating in areas that may be hazardous or where

visibility is poor, designate a person to direct the movements of the machine and traffic on the work site.

q Before moving the machine, sound the horn to warn the per-

sons standing or working in the area.

q There are blind spots behind the machine, which cannot be

seen through the rear-view mirrors 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. On request the machine can be equipped with an acoustic alarm (1) for travelling in reverse; before starting to travel in reverse, make sure that the acoustic alarm is functioning perfectly. See "3.3.6 pos. 1 - REVERSING GEAR LEVER".

RWA00340

2.4.5 MOVING THE MACHINE

q When moving the machine, position the front bucket at about

30–40 cm from the ground; this position makes it possible to evaluate the space required for the movements more precisely and at the same time ensures the stability of the machine.

q If the front bucket control lever is to be used during travel,

avoid moving it 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 the machine has to overrun an obstacle, keep the front

equipment as close to the ground as possible and travel at low speed, in order not to overload the axles and tyres.

RKAB5830

30-40 cm

RKA13510

2.4.6 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 work with the bucket downward with respect to the

tractor.

q On hills, banks or slopes, keep the bucket very close to the

ground (20–30 cm from the ground) and in case of emergency quickly lower it to the ground to help the machine stop. Do not change direction and avoid travelling obliquely when working on slopes. It is advisable to go down or up to a flat place to perform these operations.

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 working on a slope, always check the efficiency of

the brakes, engage a low gear and the four-wheel drive.

q Do not travel down slopes in neutral; you may lose control of

the machine and cause serious injuries and even death.

q Avoid disengaging the gearshift with the push button posi-

tioned on the loader control lever.

q When travelling down a slope, engage a low gear, so that

the braking action of the engine is used to hold the machine, with no need to overload the brakes. Avoid disengaging the gearshift with the push button positioned on the gearshift control lever.

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 suddenly stop, which represents a grave risk for the safety of the operator and of the persons standing before the machine.

PRECAUTIONS TO BE TAKEN DURING WORK

20-30 cm

RKA13520

WRONG

RKA13540

CORRECT

q If the engine should stop all of a sudden, immediately lower

the bucket to the ground, brake and apply the parking brake.

RKA13650

PRECAUTIONS TO BE TAKEN DURING WORK

2.4.7 PREVENTING ELECTROCUTION

q Digging operations near overhead electric lines are extreme-

ly 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 - Get acquainted with the behaviour rules to be followed in

case of electrocution.

5 - Keep the phone number of the electric energy company

and of the nearest hospital at hand.

RWA04900

q If the work equipment gets accidentally entangled in the ca-

bles, the operator must not leave the cab until the electricity company has insulated the line.

q When carrying out this kind of operations, warn everyone

standing in the work area to maintain a safety distance 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 humidity percentage in the air. Indicatively, the distances indicated 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 (

66 kV (

154 kV (

275 kV (

min. 3 insulators)5.5 m

min. 6 insulators)6 m

min. 10 insulators)8 m

min. 19 insulators) 10 m

PRECAUTIONS TO BE TAKEN DURING WORK

2.4.8 VISIBILITY

q Switch on the headlights or the work lights as soon as visibility decreases.

q If visibility decreases due to mist, smoke or heavy rain, stop the machine in a safe position and wait for the

weather to improve until visibility becomes acceptable.

2.4.9 WORKING ON ICY OR SNOW-COVERED SURFACES

q If the ground is icy or covered with snow, the response of the machine to the movements of the steering wheel

may not be precise. To reduce the risks connected with poor manoeuvrability, proceed as follows:

1 - Engage the four-wheel drive.

2 - Travel using the accelerator smoothly and gradually.

3 - Brake smoothly and only after having slowed down by using the engine deceleration as much as possible.

4 - Absolutely avoid any sudden braking, abrupt acceleration and sudden steering with short steering radius.

q If the machine is used to clear snow or as snowplough on roads (installing the specific optional equipment and

even chains, if necessary), be careful to the road shoulders and to any object/obstacle buried in the snow (wayside posts, milestones, signs just above the asphalt, etc.).

2.4.10 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 arms and the backhoe bucket from causing any damage.

2.4.11 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 injury 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: always close the cab doors and fasten the safety belt.

PRECAUTIONS TO BE TAKEN DURING WORK

2.4.12 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 front bucket directed downwards and carry out the following operations:

1 - While keeping the machine stopped with the brakes, ap-

ply the parking brake.

2 - Dump the front bucket to the unloading position and lower

the arms until the teeth are driven into the ground.

3 - Carry out the same operations with the backhoe bucket.

4 - Stop the engine.

5 - Position wedges or safety blocks under the front and rear

wheels.

q Always rest the work equipment on the ground; if it is neces-

sary to park with lifted arms, make sure that the safety locks are engaged.

q Always engage the control lever safety locks.

NOTE

q The servo control locking button inhibits also the movements

of the backhoe when this is equipped with servo controls.

q When leaving the machine, apply the parking brake, make

sure that the cab windows are closed, remove the ignition key and finally lock the doors.

RKA13750

RKA13760

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.).

RKAB2800

RKAB2760

RKAB2780

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-off a motor vehicle

always involves potential hazards. Proceed with extreme care.

q The loading and unloading of the machine on-off the means

of transport must be carried out on a flat surface and at a safety distance from the edges of ditches or from the road side.

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

wedges.

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 side board and their distance must be suitable for the tread of the machine.

q Make sure that the ramps are securely positioned and fas-

tened to the loading board and that they have the same length.

Ramps

Max.15˚

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

trace of grease, oil, soil and ice; remove dirt from the wheels before starting to load the machine on the vehicle.

q The machine must be loaded on the vehicle with the bucket

directed forwards, that is, in the direction of advancement of the vehicle.

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 its 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 TRANSPORT

CAUTION

q During transport, the machine must be secured to the vehicle, with closed doors and windows.

q Define the route to be followed, taking in consideration the width, height and weight of the transport means and

of the machine. Make sure that the dimensions of the machine are compatible with the road and any galleries, subways, bridges, electric and telephone lines, etc.

q Keep to the regulations in force regarding the permissible width, height, weight of the machine and the transport

speed.

BATTERY

2.6 BATTERY

2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY

q Electrolytic batteries contain sulphuric acid, which can cause

burns. It can also corrode clothing and make holes in it. In case of contact with battery acid, immediately wash the involved part with plenty of water.

q Battery acid may cause blindness if it comes in contact with

the eyes. If acid accidentally gets into your eyes, wash them immediately with plenty of water and consult a doctor without delay.

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 anti-acid substances like magnesia, bicarbonate, etc., call a doctor or a poison treatment centre 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.

RWA01060

WRONG

q Before working with batteries, stop the engine and remove

the ignition key.

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 (–) cable and then the positive cable (+).

RWA01080

RWA01180

q Connect the batteries in parallel: positive to positive and

negative to negative.

q When connecting the earth cable to the frame of the ma-

chine to be started, operate as far as possible from the battery (see "3.15.3 IF THE BATTERY HAS RUN DOWN").

q Do not attempt to start the engine by causing a short-circuit

with the terminals of the starter (see "2.8.14 PRECAUTIONS CONCERNING THE STARTER").

RWA01190

PRECAUTIONS FOR EMERGENCY RECOVERY

2.7 PRECAUTIONS FOR EMERGENCY RECOVERY

q The draw hooks must be used only for the first aid and not

for towing the machine.

q Before moving the machine, make sure that the gearshift le-

ver is in neutral and disengage the four-wheel drive.

q Incorrect manoeuvres may cause serious damage, injury

and 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 removal, no one should be allowed to get near

the machines or the cable.

q Do not get astride the cable.

q Move the machine only as far as necessary to allow the re-

quired repairs to be carried out.

q Do not remove the machine in any way other than that indi-

cated in paragraph "3.15.1 HOW TO REMOVE THE MACHINE".

RKAB2830

CAUTION

q The maximum applicable force for each draw hook is F =

4854 kg.

q Use cables of the same length and pull continuously,

without jerking movements.

q The drawing force must be parallel to the machine axis

(advancement direction), in such a way as to avoid the application of sideward forces on the draw hooks.

RKAB2840

RWA05380

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 firm and level ground, engage the safety locks of the equipment and of the controls, stop the engine and apply the parking brake.

q If anyone starts the engine and operates the control levers

while the operator is servicing the machine, this may result in serious injury or even death.

q To avoid these risks, always attach warning plates to the

steering wheel, 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 door handles.

RKAB4910

2.8.2 TOOLS

q Use only the tools supplied together with the machine and

high-quality 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 clean the tools carefully and store them in the com-

partment situated in the right access platform.

DO NOT

START

ENGINE

RWA01210

RWA01310

RKAB2770

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.3 PERSONNEL

q Any maintenance operation must be carried out exclusively by authorized and duly trained personnel; specific

and personal protection measures must be adopted when grinding, welding and when using sledges or heavy hammers.

q When assembling the equipment or cylinder connection pins, use wooden, plastic or in any case not excessively

hard tools to check the centering of the holes. Do not use your fingers, since you run the risk of cutting them off.

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 a safe place and positioned in such a way as to prevent them from falling down. If they fall on someone, they may cause serious bodily harm.

q When assembling or removing any equipment, make sure

that the ropes 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 Before performing service or repairs under the machine, al-

ways lower the work equipment to the ground or in any case lower it as much as possible.

q Always lock the tyres of the machine securely.

q Avoid working under the machine if it isn’t properly support-

ed.

RWA02520

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

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 worksite clean and tidy.

q To clean the machine, use a pressurized jet of warm water or

steam and the specific 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 approx. 60 cm, in order to avoid damaging the warning plates and the pictograms. If the plates are damaged, request Komatsu or your Komatsu Dealer to send you spare plates and change them.

q Water into the electric 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, avoid using water or steam jets to clean sensors, connectors or the inside of the operator's cab.

RWA01330

2.8.7 USE OF THE ENGINE DURING MAINTENANCE

q During maintenance operations, run the engine only when indispensable. If the engine must be running (for ex-

ample, when checking the functionality of the alternator), it is advisable that someone remains seated in the driving position, so that the engine can be stopped whenever necessary.

q During maintenance operations with running engine, neither move the control locking devices from the “lock” po-

sition, nor change the position of the gearshift lever. 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

large and loose clothes.

2.8.8 PERIODICAL CHANGE OF THE SAFETY RELATED PARTS

q Periodically change the following components, which are important for safety and fire prevention:

Fuel system: fuel delivery and return pipes. Hydraulic system: main delivery pipes of the hydraulic pump. Hydraulic system: work circuit pipes from the distributor to the hydraulic cylinders. Safety belt.

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 prescribed change interval has not elapsed yet.

(See "4.6 PERIODICAL CHANGE OF THE SAFETY RELATED COMPONENTS").

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 it is necessary to have the engine running during mainte-

nance, engage the safety LOCKS of the equipment control levers, apply the parking brake and carry out any maintenance operation with the help of another person; an operator must remain on board and the words to be used during the operation must be agreed upon.

NOTE

q The servo control locking button inhibits also the movements

of the backhoe when this is equipped with servo controls.

q The maintenance personnel must be very careful not to

touch any moving part of the engine.

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

RWA02000

RKAB2760

RKAB2780

RKAB2800

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP

q Spilled fuel or oil make the ground slippery and may cause

accidents; clean any dirty area carefully and without delay.

q Always tighten the fuel tank and hydraulic oil tank safety

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 ar-

eas and refrain from smoking.

q When refuelling, hold the fuel gun firmly and keep it con-

stantly 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 in the radiator.

q If it is necessary to remove the cap with hot engine, wear

suitable clothes and protection and loosen the cap slowly, in order to release the pressure gradually.

2.8.12 USING LAMPS

q When checking the fuel, oil, coolant or battery electrolyte

levels, always use homologated explosion-proof lamps. Unsuitable lamps may cause fires or explosions.

RWA00980

RWA01340

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 cable (-) and then the posi-

tive 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

RWA01370

RKAB2850

2.8.14 PRECAUTIONS CONCERNING THE STARTER

q Start the engine only when correctly seated in the driving po-

sition.

q Do not attempt to start the engine by causing a short-circuit

with the terminals of the starter. This may cause fires, serious injury and even death in case of sudden or accidental movements of the machine.

RWA04890

RKAB2860

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.15 HANDLING HIGH-PRESSURE PIPES

q Do not bend high-pressure pipes or rub them with sharp or abrasive objects.

Do not use any bent or cracked pipes 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 to service or inspect the hydraulic circuit, it is advisable to lower the equipment to the ground and completely release the pressure and also the residual pressure present in the tank.

q For this reason, always wear goggles and thick gloves dur-

ing the inspections and use a piece of cardboard or a sheet of plywood to check for oil leakages.Small leakages from pipes under pressure and the resulting jets are extremely dangerous, since they can perforate the skin and get in the blood circulation or injure the eyes.

q If you are struck by a jet of high-pressure oil or are injured,

even if slightly, consult a doctor without delay.

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 operations, the

engine coolant, the oil and all the components are hot and the hydraulic circuits are under pressure. In these conditions, if the coolant, the hydraulic oil or the engine oil are to be drained in order to change them or the filters, there are serious risks of injury and burns. Wait for the temperature to lower within the normal operating range (40–45) before carrying out the maintenance operations in accordance with the procedures indicated in the relevant sections of this manual.

RWA00990

2.8.18 HYDRAULIC ACCUMULATOR

The hydraulic accumulator contains pressurized nitrogen. When carrying out any operation on the accumulator, proceed with the utmost care, in order to avoid explosions and consequently serious injury and even death. For this reason, keep to the following instructions:

q do not remove the accumulator;

q do not use sparks or naked flames;

q do not make holes in the accumulator, do not weld or use ox-

yhydrogen flames;

q do not hit or press the accumulator;

q when disposing of the accumulator, take care to release the

gas it contains. Have this operation carried out only by a Komatsu Dealer.

2.8.19 COOLING FAN AND FAN BELT

q Be careful to the revolving parts and do not allow anyone to

get too close to these components, since clothes or parts of the body may get caught into them.

q If hands, clothes, or tools become entangled in the fan

blades or the fan belt, they may be cut off, torn or seriously injured/damaged; for this reason, avoid touching any revolving part.

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

RKA12540

2.8.20 WASTE MATERIALS

q Do not dispose of used oil in the sewer system, rivers, etc.

q Always put used oil in containers. Do not drain used oil di-

rectly on the ground.

q Keep to the laws and regulations in force when disposing of

harmful substances such as oil, fuel, solvents, used filters, gaskets, electric wires and batteries.

WARNING

q Oils, filters, coolant, gaskets, electric wires and batter-

ies are considered special waste and must be collected and disposed of according to the regulations in force.

q The combustible material of some components may be-

come extremely dangerous if it burns. For this reason, avoid any contact of burnt material with your skin or eyes and do not inhale the fumes produced.

RWA01660

RWA01670

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.21 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS

DANGER

q Some components of the machine contain polymers and elastomers (Viton sealing rings, Teflon rings,

piston seals made of fluoroelastomers, electric cable insulating materials, etc.). At room temperature and up to approximately 200°C these materials can be handled without taking any precautions, since they are completely inert. However, if these materials are burnt, they release highly toxic gases. Once these materials have cooled down, they must be collected in tight bags, using heavy waterproof gloves; gloves and materials must be disposed of in a differentiated manner in compliance with the laws in force. The contaminated part of the machine must be washed with highly alkaline detergents and then with a solution made of detergent and water.

q Avoid burning seals, electric cables, sealing rings.

q Dispose of elastomeric and polymeric waste according to

the regulations in force.

q Do not touch any burnt elastomeric or polymeric waste and

in case of accidental burning avoid inhaling the toxic gases produced.

q In case of contact with the skin, immediately rinse with a so-

lution made of water and an alkaline detergent for about 30 minutes and then contact a poisoning treatment center without delay.

RKA13780

2.8.22 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 sidewalls and tread for dents, cuts, broken plies or other defects.

q Have the tyres checked and serviced by specialized person-

nel.

q Inflate the tyres using a protection structure and a pneumatic

inflating gun with extension complete with pressure gauge.

q Make sure that there is nobody in the vicinity before starting

to inflate a tyre. Stand beside the tyre to inflate it.

q Do not exceed the inflation pressures prescribed for the sin-

gle types of tyre and make sure that all the tyres have the same pressure.

RWA01680

2.8.23 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

q When the machine is stopped at the end of work, the ex-

haust pipe (1) and the tailpipe (2) are very hot. In these conditions, if any maintenance operation has to be carried out, the operator runs the risk of being burned or injured. Carry out any maintenance operation only when these parts have cooled down and in any case always use thick gloves.

q Pay the utmost attention when installing the tailpipe (2) on

the exhaust pipe (1), since the former must be positioned correctly with the outlet of the exhaust gases directed toward the front part of the machine and inclined 60° outwards. This position serves to prevent the exhaust gases from being directed towards the cab and therefore towards the operator.

RKAB2870

2.8.24 PRECAUTIONS TO BE TAKEN WHEN USING 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 must not exceed 1% of the total quantity of oil).

q Biodegradable oil can be used only in the hydraulic system; it cannot be used for the engine, the transmissions,

the braking system, etc.

q Before introducing 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 40°C, 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 "4.8.6.a CHECKING THE HYDRAULIC OIL LEVEL").

THIS PAGE WAS INTENTIONALLY LEFT EMPTY

THE MACHINE AND ITS OPERATIONS

SAFETY LOCKS

3.1 SAFETY LOCKS

DANGER

q If it is necessary to carry out any maintenance operation or to stop the machine with lifted loader arm,

always engage the mechanical safety retainer and lock the control lever.

q When travelling on roads, always engage the mechanical lock, lock the control lever in order to keep the

front bucket in a stable position and use the front bucket swing lock and the teeth guard.

q When travelling on roads or when the backhoe is not going to be used, always connect the boom to the

safety lock, fold the arm and the bucket completely and lock both the swing and the control lever. On machines equipped with backhoe servo controls, the movements are inhibited by the servo control locking button (see "3.3.2 pos. 12 - SERVO CONTROL LOCKING BUTTON").

q Non-compliance with these rules may cause serious damage in case of accidental lowering or rotation

of the equipment.

3.1.1 FRONT LOADER LOCKS

The loader arm is provided with two safety locks that have two distinct essential functions:

a) SAFETY LOCK (1) for the position of the arm when the

machine is subjected to maintenance on the propeller unit and inspection of the hydraulic system equipment and of the auxiliary equipment housed in the engine compartment and in any case to the inspections and maintenance operations that must be carried out with lifted arm (A).

b) SAFETY LOCK (2) for the position of the arm when the

machine is travelling on roads (B).

RKAB5880

It is important to remember that in work conditions the safety lock (1) must be positioned against the arm (C) and secured in that position by means of the safety pin (3), while the safety lock (2) must be stored in the tool box positioned in the operator's cab, inside the right access platform.

IMPORTANT

q The safety locks (1-2) must always adhere to the rods of

the hydraulic cylinders, on whose eyes they are applied.

q The safety locks must be positioned definitively by

bringing the contact surfaces against each other with a slow and continuous movement, in such a way as not to damage the cylinder head surfaces.

q When the safety locks are in their definitive position, se-

cure them with the safety pins (3).

RKA13800

RKAB5890

The other applications of the safety locks concern:

a) Installation of the front bucket swing lock (1).

b) Locking position of the button inhibiting the front loader

control (2) (LED on).

SAFETY LOCKS

RWAA0770

c) Installation of the teeth guard (3).

RKAB2880

RKA13810

SAFETY LOCKS

3.1.2 BACKHOE LOCKS

The backhoe is held completely lifted by a single coupling that does not allow the boom to be lowered. The other safety device regards the swing, which is prevented, both in the central and in the folded position, by means of a pin.

To lock the boom, proceed as follows:

1 - Fold the bucket and arm completely.

2 - Press the button (1) (LED on) to raise the safety lock (3).

3 - Lift the boom completely and release the button (1) (LED

off) to engage the safety lock to the boom.

4 - Rotate the boom and insert the swing lock pin (4).

RKAB2900

RKAB2890

RKAB2910

RKAB2920

5 - Raise the stabilizers completely and couple the safety

chains (5) to the stabilizers. The controls are inhibited by the servo control locking button (2) (LED on).

6 - Stop the engine and shift the levers (6) to settle the safety

locks.

7 - Inhibit the movements of the backhoe control levers by

shifting the lever (7) to the locking position.

NOTE

q On machines equipped with backhoe servo controls, the

movements are inhibited by the servo control locking button (see "3.3.2 pos. 12 - SERVO CONTROL LOCKING BUTTON")

SAFETY LOCKS

RKA13820

RKAB2930

GENERAL VIEWS

3.2 GENERAL VIEWS

3.2.1 FRONT GENERAL VIEW

RIGHT

FORWARD

1 - Front bucket

2 - Bucket dumping cylinder

3 - Bucket lifting arm

4 - Cab

5 - Hydraulic oil tank

LEFT

6 - Rear axle

7 - Fuel tank

8 - Lifting cylinder

9 - Front axle

10 - Backhoe bucket cylinder.

RKAB5630

3.2.2 BACKHOE GENERAL VIEW

GENERAL VIEWS

RIGHT

FORWARD

1 - Bucket

2 - Arm

3 - Boom

4 - Arm cylinder

5 - Boom cylinder

6 - Revolving support

LEFT

9 810

RKAB5730

7 - Right access platform and tool box

8 - Backhoe sliding guides

9 - Stabilizers

10 - Backhoe locking cylinders

11 - Boom swing cylinders

12 - Sliding plate

GENERAL VIEWS

3.2.3 CAB INSIDE GENERAL VIEW

3.2.3.1 CAB INSIDE GENERAL VIEW (mechanical backhoe controls)

1 - Reversing gear lever

2 - Steering wheel

3 - Front dashboard

4 - Direction selector - dimmer switch

5 - Gearshift lever

6 - Steering wheel adjustment lock

7 - Accelerator pedal

8 - Brake pedals

9 - Side dashboard

10 - Front loader control lever

11 - Parking brake

12 - Hand accelerator

13 - Arm and swing control lever

Standard version “ISO pattern controls”)

- Boom and swing control lever (On request “Komatsu pattern and X-pattern controls”)

14 - Boom and bucket control lever

(Standard version “ISO pattern controls”)

- Arm and bucket control lever (On request “Komatsu pattern and X-pattern controls”)

15 - Right stabilizer control lever

16 - Left stabilizer control lever

RKAB2940

RKAB2950

RKAB2980

RKAB2960

RKAB2970

3.2.3.2 CAB INSIDE GENERAL VIEW (backhoe servo controls)

GENERAL VIEWS

1 - Reversing gear lever

2 - Steering wheel

3 - Front dashboard

4 - Direction selector - dimmer switch

5 - Gearshift lever

6 - Steering wheel adjustment lock

7 - Accelerator pedal

8 - Brake pedals

9 - Side dashboard

10 - Front loader control lever

11 - Parking brake

12 - Hand accelerator

13 - Arm and swing control lever

(Standard version “ISO pattern controls”)

- Boom and swing control lever (On request only with Pattern Change “Komatsu pattern controls”)

14 - Boom and bucket control lever

(Standard version “ISO pattern controls”)

- Arm and bucket control lever (On request only with Pattern Change “Komatsu pattern controls”)

15 - Left stabilizer control lever

16 - Right stabilizer control lever

RKAB2940

RKAB2950

RKAB2980

RKAB2960

RKA15070

INSTRUMENTS AND CONTROLS

3.3 INSTRUMENTS AND CONTROLS

3.3.1 FRONT INSTRUMENTS

1 - Low fuel warning light 8 - Low oil pressure or braking system failure warning light

2 - Four-wheel drive warning light 9 - General alarm warning light

3 - Differential locking warning light 10 - High beam warning light

4 - Parking brake warning light 11 - Low beam warning light

5 - Transmission oil temperature warning light 12 - Parking lights and instrument lights warning light

6 - Left direction indicator warning light 13 - Direction selector, dimmer switch, horn, blinking, front

7 - Right direction indicator warning light

windshield wiper/washer

RKA13850

1 - LOW FUEL WARNING LIGHT

It comes on when about 17 litres of fuel are left in the tank and therefore it is necessary to refuel as soon as possible.

RKA13860

2 - FOUR-WHEEL DRIVE WARNING LIGHT

It comes on when the four-wheel drive is engaged.

3 - DIFFERENTIAL LOCKING WARNING LIGHT

It comes on when the differential is locked by means of the push button positioned on the loader control lever (see "3.3.6 pos. 11 - DIFFERENTIAL LOCKING PUSH BUTTON").

INSTRUMENTS AND CONTROLS

RKA13870

4 - PARKING BRAKE WARNING LIGHT

It comes on when the parking brake is applied.

5 - TRANSMISSION OIL TEMPERATURE WARNING

LIGHT

It comes on and activates the acoustic alarm when the transmission oil exceeds the maximum temperature allowed; when it comes on, immediately stop the machine, put it in neutral and let it cool down with the engine idling at approximately 1200 rpm until the warning light goes out. If this occurs repeatedly, have the machine inspected and if necessary repaired by an authorized repair shop.

RKA13880

RWA20230

RKA01810

INSTRUMENTS AND CONTROLS

6 - LEFT DIRECTION INDICATOR WARNING LIGHT

It flashes on and off when the indicator (13) is operated to turn to the left, while it comes on at the same time as the warning light (7) when the hazard flashers are activated (see "3.3.2 pos. 16 - HAZARD FLASHERS").

7 - RIGHT DIRECTION INDICATOR WARNING LIGHT

It flashes on and off when the indicator (13) is operated to turn to the right, while it comes on at the same time as the warning light (6) when the hazard flashers are activated (see "3.3.2 pos. 16 - HAZARD FLASHERS").

RKA13890

8 - LOW OIL PRESSURE OR BRAKING SYSTEM FAIL-

URE WARNING LIGHT

It comes on to indicate that the brake oil pressure is low or that there is no oil in the reservoir due to leakages.

9 - GENERAL ALARM WARNING LIGHT

This warning light comes on:

a - for about 3 seconds, during the general warning light

check that is performed every time the machine is started;

b - when the maximum temperature allowed for the engine

coolant is exceeded;

c - when the engine oil pressure is low.

RKA13900

RYA13700

RKA00030

10 - HIGH BEAM WARNING LIGHT

It comes on when the high beam is operated through the dimmer switch - pos. (13).

11 - LOW BEAM WARNING LIGHT

It comes on when the low beam is operated with two clicks of the switch (17) positioned on the side dashboard (see "3.3.2 pos. 17 - PARKING LIGHTS AND LOW BEAM SWITCH").

INSTRUMENTS AND CONTROLS

RKA13910

12 - PARKING LIGHTS AND INSTRUMENT LIGHTS WARN-

ING LIGHT

It comes on when the parking lights are operated with one click of the switch (17) positioned on the side dashboard (see "3.3.2 pos. 17 - PARKING LIGHTS AND LOW BEAM SWITCH").

13 - DIRECTION SELECTOR, DIMMER SWITCH, HORN,

BLINKING, FRONT WINDSHIELD WIPER/WASHER

This is a combined switch positioned under the steering wheel, on the right side, and controls the following functions:

A - Left direction indicator

B - Right direction indicator

C - Horn

D - Low beam/high beam switch-over

E - High beam blinking

F - Windshield wiper

G - Windshield washer

RKA13920

RKA00970

RKAB3000

INSTRUMENTS AND CONTROLS

3.3.2 SIDE INSTRUMENTS

RKA13930

1 - Fuel level indicator

2 - Engine coolant temperature indicator

3 - Revolution counter - Hour meter

4 - Hydraulic oil filter clogging warning light

5 - Generator warning light

6 - Glow plug preheating warning light

7 - Engine coolant temperature warning

light

8 - Engine oil pressure warning light

9 - Air filter clogging warning light

10 - Revolving light warning light

11 - Acoustic alarm

12 - Servo control locking button

13 - Backhoe speed control button

14 - Backhoe sliding lock switch

15 - Backhoe boom lock switch

16 - Hazard flashers

17 - Low beam and parking lights switch

18 - Four-wheel drive switch

19 - Rear horn

20 - Safety valve switch (if installed)

21 - Load stabilizer system switch

(if provided)

22 - Optional equipment switch (if provided)

23 - Hydraulic hand hammer switch

(if provided)

24 - Ignition switch

25 - Fan switch

26 - Air conditioner switch (if provided)

RKAB4290

RKAB3300

1 - FUEL LEVEL INDICATOR

It indicates the fuel level in the tank and functions only when the ignition key is in position «I».

IMPORTANT

q If the indicator reaches the red low fuel area during

work, stop the machine and provide for refuelling.

q The warning light (1) positioned on the front instrument

panel signals when the fuel level is too low (see "3.3.1 pos. 1 - LOW FUEL WARNING LIGHT").

2 - ENGINE COOLANT TEMPERATURE INDICATOR

It indicates the engine coolant temperature, which normally must be included between 80°C and 85°C. If the indicator reaches the red area, indicating that the temperature is too high, the acoustic alarm sends out a continuous signal, the warning light (7) comes on and the general alarm warning light flashes on and off (see "3.3.1 pos. 9 GENERAL ALARM WARNING LIGHT").

INSTRUMENTS AND CONTROLS

RKAB4340

3 - REVOLUTION COUNTER - HOUR METER

This is a combined instrument that indicates the engine speed with a pointer, while the number of operating hours appears in the lower displays. The count is continuous and the hour number is increased by one when the engine has worked for 1 hour, independently on the engine speed. The hour counter keeps counting even if the machine isn’t working or travelling. The reading must be considered valid for the calculation of the maintenance intervals.

RKAB4350

RKAB4360

INSTRUMENTS AND CONTROLS

4 - HYDRAULIC OIL FILTER CLOGGING WARNING LIGHT

It comes on when the hydraulic oil filter is clogged and must be replaced (see "4.8.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER").

5 - GENERATOR WARNING LIGHT

This warning light comes on, together with the acoustic alarm, when the starting circuit is energized and goes out when the engine exceeds the idling rpm; if this warning light remains on even when the engine is running at the normal operating speed, this means that the alternator is not working and the battery is not charged correctly.

RWA22340

IMPORTANT

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.

6 - GLOW PLUG PREHEATING WARNING LIGHT

It comes on when the ignition key is turned to position « » for the cold start of the engine (see "3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES").

7 - ENGINE COOLANT TEMPERATURE WARNING LIGHT

This warning light comes on, together with the acoustic alarm, when the engine coolant exceeds the maximum temperature allowed; in this case, let the engine idle (approx. 1200 rpm) until it stops. If this inconvenience occurs again, make sure that the radiator is clean.

RWA07150

RWA07160

RKA13940

8 - ENGINE OIL PRESSURE WARNING LIGHT

This warning light comes on, together with the acoustic alarm, when the engine is not running and the starting circuit is operated and goes out as soon as the engine lubrication circuit is pressurized. If it does not go out or comes on when the engine is running, stop the machine immediately and try to find the cause of the failure.

9 - AIR FILTER CLOGGING WARNING LIGHT

It comes one when the engine air filter needs cleaning (see "4.8.1.a CHECKING, CLEANING OR CHANGING THE ENGINE AIR FILTERS").

INSTRUMENTS AND CONTROLS

RWA07130

10 - REVOLVING LIGHT WARNING LIGHT

It comes on when the revolving light is operated by means of the switch positioned on the upper right side of the cab (see "3.3.5 pos. 2 - REVOLVING LIGHT SWITH").

11 - ACOUSTIC ALARM

The acoustic alarm starts when the circuits are energized with the ignition key (turned to position « ») and stops automatically after the automatic check on the warning lights. The sounding of the alarm when the machine is working signals the following anomalies:

• Insufficient engine oil pressure

• Overheating of the engine cooling circuit

• Overheating of the transmission oil

• Faulty alternator or worn belt

• Incorrect position of the seat while the machine is moving

RWA31710

RKA01800

RKA01070

INSTRUMENTS AND CONTROLS

12 - SERVO CONTROL LOCKING BUTTON

WARNING

q When travelling on roads, always engage the servo con-

trol locking device.

This button has the function to inhibit the servo controls and must be used when the machine travels on roads and as safety lock when leaving the driver’s seat or parking the machine. To lock the servo controls, press the button (12) (LED on). Press the button again (LED off) to release the controls.

NOTE

q Whenever the machine is started, the controls are locked

automatically (LED on); press the button (LED off) to use the controls.

q For safety reasons, the servo controls are locked automati-

cally (LED on) when the seat is rotated by the operator to change driving position. The servo controls are automatically released (LED off) when the rotation has been completed and the seat is fixed in the correct driving position (front or rear).

q In the version with backhoe servo controls, this button

serves to lock the backhoe controls, too.

RKAB4370

13 - BACKHOE SPEED CONTROL BUTTON

This button allows the quantity of oil delivered by the hydraulic pump to be selected. Whenever restarted, the machine automatically selects the POWER mode (LED on), even if when it stopped the selected mode was ECONOMY. This position makes it possible to use the maximum oil delivery and is indispensable for a correct use of the backhoe. When the button is pressed (LED off), the ECONOMY operating mode is selected. To return to the POWER mode (LED on), press the button again. The machine passes automatically from POWER to ECONOMY mode when the forward or the reverse gear are engaged (reversing gear lever forward or backward). To return to the POWER mode, shift the lever back to the neutral position.

14 - BACKHOE SLIDING LOCK SWITCH

This switch has the function to release the backhoe unit from the sliding guides, in such a way as to make it possible to change the position of the backhoe with respect to the machine. The backhoe unit is generally fixed on the guides and the switch is not operated (LED off). When pressed, the switch comes on and releases the unit from the guides, thus allowing the backhoe to slide; once the desired position has been reached, press the switch again to fix the backhoe unit (LED off).

POWER

RKAB4380

RKA13980

15 - BACKHOE BOOM LOCKING BUTTON

This is a button that automatically returns to position OFF and is used to couple the safety lock to the boom when the backhoe is not going to be used or when the machine travels on roads. Press the button (LED on) to lift the safety lock; this is indispensable to position the boom correctly before the coupling operation. Release the button (LED off) to lower the lock and couple it to the boom. For the use of this button, see "3.6.1.1 pos. 8 - BACKHOE BOOM LOCKING BUTTON".

16 - HAZARD FLASHERS

This button operates both direction indicators at the same time and must be used whenever, while travelling on roads, the machine is temporarily parked/stopped on the roadway or in any case in anomalous position.

INSTRUMENTS AND CONTROLS

RKA13990

17 - PARKING LIGHTS AND LOW BEAM SWITCH

This is a two-position switch; with one click it switches on the parking lights and instruments, with two clicks it switches on the low beam. The parking lights can be switched on even with the machine at rest.

18 - FOUR-WHEEL DRIVE SWITCH

When pressed (LED on), this switch engages the four-wheel drive. When the switch is pressed, also the warning light pos. (2) on the front instrument panel comes on (see "3.3.1 pos. 2

- FOUR-WHEEL DRIVE WARNING LIGHT"). When pressed again (LED off), it disengages the four-wheel drive.

RWA20210

RKA01820

IMPORTANT

q When travelling at high speed and on roads, disengage

the four-wheel drive.

q The four-wheel drive is automatically engaged when the

brake pedals are pressed, and only with the 4

gear en-

gaged.

RKA13870

INSTRUMENTS AND CONTROLS

19 - REAR HORN

It serves to warn the persons in the surrounding area before starting work and in case of danger when working with the backhoe.

20 - ELECTRIC SAFETY VALVE SWITCH (if installed)

When pressed (LED on), this switch deactivates the safety valves installed on the front loader cylinders. When pressed again (LED off), it reactivates the safety valves.

IMPORTANT

q Always deactivate the electric safety valves when the

load stabilizer system “LSS” is operated. For further information regarding the “LSS”, see "6.11 LOAD STABILIZER SYSTEM (LSS) (Optional)".

RKA14010

21 - LOAD STABILIZER SYSTEM SWITCH “LSS”

(if provided)

Pressing the switch (LED on) enables the load stabilizer system LSS. When the switch is in this position the battery can be recharged and the pressure is kept constant. For further information on the LSS system, see "6.11 LOAD STABILIZER SYSTEM (LSS) (Optional)". Press the switch again (LED off) to disable the load stabilizer system.

22 - OPTIONAL EQUIPMENT SWITCH (if provided)

RKA14020

RKA14030

23 - HYDRAULIC HAND HAMMER SWITCH (if provided)

When pressed (LED on), this switch enables the hydraulic circuit of the hand hammer. When pressed again (LED off), it disables the circuit.

24 - IGNITION SWITCH

The ignition switch is a rotary key switch with four positions marked with the following symbols « » - (OFF) - « » «» (START). For further details on the use of this switch, see "3.6.2 STARTING THE ENGINE").

INSTRUMENTS AND CONTROLS

RKA13960

25 - FAN SWITCH

It is a three-speed switch and operates the fan motor. Turn the switch clockwise to increase the fan speed. If operated after opening the cock installed on the heater, it ensures the circulation of warm air and serves as heating switch (see "3.5.3 VENTILATION AND HEATING"). The temperature of the air delivered by the heater can be adjusted through the knob positioned under the switch. Turn the knob clockwise to increase the temperature and counterclockwise to reduce it. If the machine is provided with air conditioning system, the same knob can be used to adjust the air flow and therefore the temperature inside the cab. For further information, see "3.5.4 AIR CONDITIONER (if installed)".

26 - AIR CONDITIONER SWITCH (if provided)

Press the switch (LED on) to start the compressor of the air conditioner. For further information on the operation of the air conditioning system, see "3.5.4 AIR CONDITIONER (if installed)". Press the switch again (LED off) to stop the air conditioner.

RWA23290

RWA07170

IMPORTANT

q It is advisable to start the air conditioner only with low

engine rpm and not during acceleration, to avoid damaging the system or breaking the compressor drive belt.

RYA13780

INSTRUMENTS AND CONTROLS

3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER

1 - Declutch push button

2 - Differential locking push button

3 - 4in1 bucket opening push button

4 - 4in1 bucket folding push button

5 - Front loader speed control push button

1 - DECLUTCH PUSH BUTTON

This push button is used to transform all the engine power into the hydraulic power necessary to lift the material. (See "3.3.6 pos. 10 - DECLUTCH PUSH BUTTON").

RKAB5231

2 - DIFFERENTIAL LOCKING PUSH BUTTON

This push button must be used with low gears and reduced speed, only when it is necessary to make the rear driving wheels integral with each other in case of slipping (see "3.3.6 pos. 11 - DIFFERENTIAL LOCKING PUSH BUTTON"). The warning light (3) on the front instrument panel (see "3.3.1 pos. 3 - DIFFERENTIAL LOCKING WARNING LIGHT") indicates that the push button is in use.

3 - 4IN1 BUCKET OPENING PUSH BUTTON

Press the push button to open the bucket; when the push button is released, the bucket stops. (See "3.3.6 pos. 12 - 4 IN1 BUCKET OPENING PUSH BUTTON").

RKA14040

RKA13880

RKA14050

4 - 4IN1 BUCKET FOLDING PUSH BUTTON

Press the push button to fold the bucket; when the push button is released, the bucket stops. (See "3.3.6 pos. 13 - 4 IN1 BUCKET FOLDING PUSH BUTTON").

5 - FRONT LOADER SPEED CONTROL PUSH BUTTON

This button is used to increase the speed of the front loader movements.

INSTRUMENTS AND CONTROLS

RKA14060

3.3.4 PUSH BUTTON ON THE GEARSHIFT LEVER

1 - DECLUTCH PUSH BUTTON

This push button is used to shift gears when the machine is travelling. (See "3.3.6 pos. 15 - DECLUTCH PUSH BUTTON").

RKA14070

RKAB3120

INSTRUMENTS AND CONTROLS

3.3.5 CAB SWITCHES AND ELECTRIC ACCESSORIES

1 - FRONT WORK LIGHT SWITCH

This switch enables the front work lights installed on the cab.

IMPORTANT

q When travelling on roads, switch off the work lights.

2 - REVOLVING LIGHT SWITH

This switch must be operated when it is necessary to travel on roads and after connecting the light to the outlet installed on the cab roof.

RKAB4620

RKAB4630

3 - REAR WORK LIGHT SWITCH

This switch enables the rear work lights installed on the cab.

IMPORTANT

q When travelling on roads, switch off the work lights.

4 - REAR WINDSHIELD WIPER SWITCH

This switch operates the rear windshield wiper.

RKAB4640

RKAB4650

5 - REAR WINDSHIELD WASHER SWITCH

This switch, with automatic return to the OFF position, operates the rear windshield washer.

6 - OVERHEAD LAMP

The overhead lamp is used to check the instruments and the inside of the cab when visibility is scarce.

INSTRUMENTS AND CONTROLS

RKAB4660

7 - POWER OUTLET

The 12V power outlet is in compliance with the ISO 4165-1979 standard. It is used for the connection of the revolving light, of the inspection lamp when maintenance operations are to be carried out and visibility is scarce, and of the emergency light. The outlet is powered with the revolving light switch. (See "3.3.2 pos. 13 - BACKHOE SPEED CONTROL BUTTON").

8 - CIGARETTE LIGHTER SOCKET

The socket (8) is positioned on the lower part of the side dashboard and is powered by a 12V supply. It is used for the cigarette lighter and is perfectly compatible with the cigarette lighters available on the market. It can also be used to recharge mobile phones. Before use, remove the protection cap.

RKAB3050

RKAB3060

RKAB3070

INSTRUMENTS AND CONTROLS

9 - BATTERY DISCONNECTION SWITCH (if provided)

The battery disconnection switch (9) is positioned on the left side of the machine, inside the engine compartment, and can be reached by opening the engine hood (see "3.5.1 ENGINE HOOD"). It is possible to interrupt the passage of current from the battery to the electric system of the machine by turning the switch counterclockwise and releasing it. Always interrupt the passage of current before carrying out any operation on the battery or the electric system and before carrying out any welding operation on the machine. To restore the electric contact, put back the switch and turn it clockwise.

10 - APERTURE FOR THE INSTALLATION OF A CAR RA-

DIO (if provided)

If the machine is provided with an aperture for the installation of a car radio, remove the cover (10) and install the radio.

RKA15790

IMPORTANT

q For use, keep to the instructions contained in the book-

let supplied together with the radio.

RKAB4670

3.3.6 MACHINE CONTROLS

3.3.6.1 MACHINE CONTROLS (version with mechanically-controlled backhoe)

INSTRUMENTS AND CONTROLS

1 - Reversing gear lever

2 - Brake pedals

3 - Accelerator

4 - Front loader control lever

5 - Gearshift lever

6 - Parking brake

7 - Hand accelerator

8 - Backhoe boom locking button

9 - Backhoe sliding lock switch

10 - Declutch push button

11 - Differential locking push button

12 - 4in1 bucket opening push button

13 - 4in1 bucket folding push button

14 - Front loader speed control push button

15 - Declutch push button

RKAB3080

RKAB3090

RKAB3100

RKAB3110

RKAB3120

INSTRUMENTS AND CONTROLS

16 - Left stabilizer control lever

17 - Right stabilizer control lever

18 - Left backhoe control lever

19 - Right backhoe control lever

RKAB3140

RKAB3130

3.3.6.2 MACHINE CONTROLS (version with servo-assisted backhoe)

INSTRUMENTS AND CONTROLS

1 - Reversing gear lever

2 - Brake pedals

3 - Accelerator

4 - Front loader control lever

5 - Gearshift lever

6 - Parking brake

7 - Hand accelerator

8 - Backhoe boom locking button

9 - Backhoe sliding lock switch

10 - Declutch push button

11 - Differential locking push button

12 - 4in1 bucket opening push button

13 - 4in1 bucket folding push button

14 - Front loader speed control push button

15 - Declutch push button

RKAB3080

RKAB3090

RKAB3100

RKAB3110

RKAB3120

INSTRUMENTS AND CONTROLS

16 - Left stabilizer control switch

17 - Right stabilizer control switch

18 - Left backhoe control lever

19 - Right backhoe control lever

20 - Pattern change control lever (if provided and only for the

version with servo-assisted backhoe)

RKAB3140

RKA15080

INSTRUMENTS AND CONTROLS

1 - REVERSING GEAR LEVER

WARNING

q When it is necessary to park or leave the machine unattended, even if temporarily, shift the lever to posi-

tion (N) and always apply the parking brake.

q The machine is equipped with an acoustic alarm that is activated if the operator, with the engine run-

ning, shifts the reversing gear lever (1) to position F or R with the seat rotated in any position different from the correct driving position. This is a danger signal, since it is absolutely forbidden to move the machine while working with the backhoe equipment or in any case with the seat rotated by 180° with respect to the regular driving position. Remember that the operator is allowed to move the machine only when seated in the correct driving position, with locked seat and fastened safety belt.

q Non-compliance with these rules may cause serious accidents.

IMPORTANT

q Operate the lever only when the engine is running at low speed.

q The engine can be started only with the lever in neutral position (N).

q If the operator deems it necessary, the machine may also be equipped with an acoustic alarm for move-

ments in reverse. This device can be installed on a special area in the rear part of the frame (see "2.4.4 CHECKS FOR TRAVELLING IN REVERSE"); before travelling in reverse, make sure that the acoustic alarm functions perfectly. To check the functionality of this acoustic alarm, proceed as follows:

- start the machine (see "3.6.2 STARTING THE ENGINE");

- press the brake pedals;

- shift the reversing gear lever (1) to the reverse position R. If the alarm doesn’t work, have the machine checked by your Komatsu Dealer.

By lifting this lever and rotating it on the vertical axis, it is possible to select:

F - the forward travel, if the lever is shifted FORWARD

R - the reverse, if the lever is shifted BACKWARD

RKAB3150

INSTRUMENTS AND CONTROLS

2 - BRAKE PEDALS

WARNING

q The brake pedals must always be connected when the

or 4th gear is engaged and when the machine travels

on roads.

q Non-compliance with this rule may result in serious ac-

cidents.

The machine is provided with two split brake pedals that make it possible to turn sharply in small work areas with many obstacles; with the right pedal it is possible to make sharp turns to the right, with the left pedal it is possible to make sharp turns to the left. When the pedals (2) are used individually, reduce the speed and keep the bucket as low as possible. The pedals must always be connected with each other by means of the connection pin (A) when the high gears are engaged and when the machine travels on roads.

IMPORTANT

q When the machine is running at high speed and only

with the 4th gear engaged, the braking power is increased with the automatic engagement of the fourwheel drive.

RWA13950

RWA13960

3 - ACCELERATOR

Use the accelerator with care, especially when the machine is under strain or is working in difficult conditions. Avoiding useless accelerations means reducing consumption and extending the service life of both the engine and the machine.

4 - FRONT LOADER CONTROL LEVER

INSTRUMENTS AND CONTROLS

WARNING

q Before carrying out any manoeuvre with this lever, the

operator must be seated in the driving position, with fastened safety belt.

q If the loader control lever has to be used during travel,

avoid any abrupt and quick movement that may affect the balance of the machine and make it difficult to drive.

q If it is necessary to leave the machine on a slope, take

all the precautions aimed at preventing any uncontrolled movement of the machine itself. (See "3.7 PARKING THE MACHINE").

q Before leaving the operator’s seat, lower the bucket to

the ground and engage the safety lock before stopping the engine.

The front loader control lever (4) is positioned on the operator’s right and controls the lifting and lowering of the arm and the folding and dumping of the bucket according to the orthogonal movements listed below. If the machine is properly equipped, the shifting of the lever to position E (one click) sets the loader to a free, or floating position, that is, to a position in which it can automatically follow the undulation of the ground. Shifting the lever (4) 45° towards the axis of the machine (F) activates the “Return-to-dig” device, which controls the lowering of the loader arm and at the same time folds the bucket in loading position. As soon as the bucket touches the ground, the “Return-to-dig” device is disconnected and the machine returns to normal operating conditions.

RWA33710

N - Neutral

A - Bucket folding

B - Arm lowering

C - Bucket dumping

D - Arm lifting

Only with the appropriate equipment:

E - Free (floating) arm

F - Self-leveling (return-to-dig)

INSTRUMENTS AND CONTROLS

If the lever is shifted following an inclined direction with respect to the machine axes, simultaneous movements, proportional to the inclination angle, are obtained, since the two hydraulic distributors responsible for the single functions are operated at the same time.

N - Neutral

A - Arm lowering - Bucket folding

B - Arm lowering - Bucket dumping

C - Arm lifting - Bucket dumping

D - Arm lifting - Bucket folding

IMPORTANT

q All movements are inhibited when the safety button (A)

is in locking position (LED on) (see "3.3.2 pos. 12 SERVO CONTROL LOCKING BUTTON").

CAUTION

q When the machine travels on roads, the servo control

locking device must always be activated.

RWA00550

RKAB4450

5 - GEARSHIFT LEVER

INSTRUMENTS AND CONTROLS

WARNING

q Since no mechanical connection is provided between

the gearbox and the engine, if the machine is parked on a slope it can move freely even with engaged gears; for this reason, always apply the parking brake, in order to avoid any damage.

q Engage the gears only with the engine running at low

speed.

q Avoid shifting up when using the machine for heavy-du-

ty applications.

q Always shift the lever to the neutral position (N) when

parking or leaving the machine unattended, even if temporarily.

By means of the lever (5) it is possible to engage one of the four available gears, which are arranged according to the diagram. The choice of the gear to be engaged is up to the operator; it is advisable to use the low gears for heavy-duty applications and to use the high gears for movements on flat surfaces or to travel at high speed. This precaution serves to protect the converter unit from dangerous overheatings.

RKAB3180

RWA03270

IMPORTANT

q During normal travel, the gears can be shifted up or

down with the declutch push button (15) pressed. (See "3.3.6 pos. 15 - DECLUTCH PUSH BUTTON").

q Before shifting down, decelerate by putting on the

brakes.

INSTRUMENTS AND CONTROLS

6 - PARKING BRAKE

CAUTION

q The parking brake must be applied whenever it is neces-

sary to leave the driving position, even if temporarily.

q The machine must be parked with the rear wheels firmly

resting on a flat surface. If one of the rear wheels is unstable or rests on a small obstacle, the machine may move.

q Periodically check the brake efficiency.

Non-compliance with these rules may cause serious accidents or even death.

q The parking brake must be released if the machine

breaks down and it is necessary to remove it.

Braking is obtained by pulling the lever completely upwards, until the safety device is coupled; release is obtained by pressing the lower safety device while releasing the lever, which automatically returns downward.

CAUTION

q The warning light 4 on the front instrument panel (see

"3.3.1 pos. 4 - PARKING BRAKE WARNING LIGHT") signals that the parking brake is applied.

q In order to ensure safety, when the parking brake is ap-

plied the functions of the reversing gear lever are inhibited (see "3.3.6 pos. 1 - REVERSING GEAR LEVER").

RKAB2800

RKAB2810

Komatsu WB93R-5 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 FOREWORD

1.2 INFORMATION ON SAFETY

1.3 INTRODUCTION

1.3.1 INTENDED USES

1.3.2 IMPROPER OR UNAUTHORIZED USE

1.3.3 MAIN CHARACTERISTICS

1.3.4 RUNNING-IN

1.4 PRODUCT IDENTIFICATION

1.4.1 MACHINE IDENTIFICATION NUMBER (PIN)

1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) (alternatively for some markets)

1.4.3 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)

1.4.4 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE

1.4.5 FRONT AXLE SERIAL NUMBER

1.4.6 REAR AXLE SERIAL NUMBER

1.4.7 TRANSMISSION SERIAL NUMBER

1.4.8 CAB SERIAL NUMBER

1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS

TABLE OF CONTENTS

2.1 SAFETY, NOISE AND VIBRATION PLATES

2.1.1 POSITION OF THE SAFETY PLATES

2.1.2 PICTOGRAMS AND RELEVANT MEANINGS

2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB

2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED

2.2 GENERAL PRECAUTIONS

2.2.1 GENERAL SAFETY RULES

2.2.2 SAFETY DEVICES AND GUARDS

2.2.4 UNAUTHORIZED MODIFICATIONS

2.2.5 LEAVING THE OPERATOR’S SEAT

2.2.6 GETTING ON AND OFF THE MACHINE

2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL

2.2.9 PREVENTING BURNS

2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER

2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT

2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT

2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE

2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT

2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE

2.3.1 SAFETY ON THE WORK SITE

2.3.2 FIRE PREVENTION

2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB

2.3.4 ROOM VENTILATION

2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS

2.4 PRECAUTIONS TO BE TAKEN DURING WORK

2.4.1 WHEN STARTING THE ENGINE

2.4.2 RULES FOR TRAVELLING ON ROADS

2.4.3 HAND SIGNALS

2.4.4 CHECKS FOR TRAVELLING IN REVERSE

2.4.5 MOVING THE MACHINE

2.4.6 WORKING ON SLOPES

2.4.7 PREVENTING ELECTROCUTION

2.4.8 VISIBILITY

2.4.9 WORKING ON ICY OR SNOW-COVERED SURFACES

2.4.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT

2.4.11 WORKING ON LOOSE GROUND

2.4.12 PARKING THE MACHINE

2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES

2.5.1 LOADING AND UNLOADING THE MACHINE

2.5.2 TRANSPORT

2.6 BATTERY

2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY

2.6.2 STARTING WITH BOOSTER CABLES

2.7 PRECAUTIONS FOR EMERGENCY RECOVERY

2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.1 WARNING PLATES

2.8.2 TOOLS

2.8.3 PERSONNEL

2.8.4 EQUIPMENT

2.8.5 WORKING UNDER THE MACHINE

2.8.6 KEEPING THE MACHINE CLEAN

2.8.7 USE OF THE ENGINE DURING MAINTENANCE

2.8.8 PERIODICAL CHANGE OF THE SAFETY RELATED PARTS

2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR

2.8.12 USING LAMPS

2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR

2.8.14 PRECAUTIONS CONCERNING THE STARTER

2.8.15 HANDLING HIGH-PRESSURE PIPES