Komatsu WB97S-2 User Manual

WEAM000704

Operation & Maintenance
Manual

WB97S-2

BACKHOE-LOADER

SERIAL NUMBER

WB97S-2 97SF11205 and up

WARNING

Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or maintain­ing this machine.
This manual should be kept inside the cab for refer­ence and periodically reviewed by all personnel
who will come into contact with the machine.

FOREWORD

CAUTION

1.1 FOREWORD

• This manual has been carr ied out by Komatsu Utility in o rder to supply thei r customers with al l the necessa ry

information on the mac hine and th e safety regulatio ns rela ted to it, t ogether with the use an d maintena nce in­structions tha t enable the o perator to exploit the capaci ty of the machine w ith optimal results a nd to keep the
machine efficient over time.

• The operation manual, together with the spare parts catalogue, is an integral par t of the mac hin e and must ac-

company it, even when it is resold, until its final disposal.

• 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 comp artment be hind the seat, where also the
ownership documents and the logbook are usually kept (see “3.5.10 TECHNICAL DOCUMENTATION”).

• 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 co nten ts c ar ef ull y m or e th an o nce, in s uc h a way as to clear l y un der st an d wha t
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 Utility or your Komatsu Utility Dealer.

• The illustrations contained in this manual may represent machine configurations available upon request.

Komatsu Utility machines are constantly improved in order to increase their efficiency and reliability; this manu­al sums up all the infor mation regarding the m ost recent techniques ap plied at the moment in which the ma­chine is marketed.
For any further and/or updated information, contact your Komatsu Utility Dealer.

• For the various maintenance phases it is advisable to consult the hour meter and in particular the maintenance

plan set on the electron ic unit of th e mach ine frequentl y. The display of the maintenance plan can be obtai ned
by means of an appropriate scre en po si tio ned on the uppe r pa rt of the front dashboard. In any case, the mai n­tenance plan can be als o consulted on the r elevant manual provided. Keep to the various maintenance i nter­vals indicated on the screen and on the use and maintenance manual.

• Over the years Komatsu Utility Dealers have gathered considerable experience in customer service.

If more information is needed , do n ot hes itate to cont act your Komatsu Utility Dealer : he always knows how to
get the best perform ance from the m achine, he ca n su ggest the u se of the e quipm ent tha t is most suit able 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.
Further more, Komatsu Utility Dealers also ens ure their assistance for the suppl y of Komatsu Utility genuine
spare parts, which alone guarantee safety and interchangeability.

• The table included in th is m anual mus t be filled i n wit h t he ma chine data, which a re th e data that must al ways

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

• The incorrect use of the machine and inappropriate maintenance operations may cause serious inju-

ries and even death.

• Operators and maintenance personnel must carefully read this manual before using the machine or

performing maintenance operations.

• Any serious accident that may occur during the use of the machine or during main tenance operat ions

is due to failure to comply with the instructions given herein.

• 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 describ ed herein, the operator
shall be responsible for his own safety and for the safety of any other person involved.

1

INFORMATION ON SAFETY

IMPORTANT

☞

1.2 INFORMATION ON SAFETY

Many accidents are caused by insuffi cient knowledge of and failure to comply with th e safety regulations pre­scribed for the maintenance operations that must be performed on the machine.
In order to avoid accidents, before star ting work and before carr ying 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, so that you can follow the instructions without making mistakes.
To identify the messages regarding safety that are included in this manual and written on the machine plates, the
following words have been used.

DANGER

CAUTION

Komatsu Utility cannot reasonably predict every circumstance that might involve a potential hazard during the op­eration or maintenance of the mac hi ne; for this reason, the safety mess ag es inclu ded in thi s manual and a ppl ied
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 can 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 Utility or your local Dealer.

• This word is used in the safety warnings in the manual and on the plates when

the situation is dangerous and it may possibly result in serious injuries or even
death.
These messages describe the safety precautions to be taken in order to avoid
any risk. Non-compliance with these instructions may also res ult in serious
damage to the machine.

• Th is word is used in the safety war n ings in the manua l and on t he p lates t o sig-

nal risks that may cause moderate damage or injuries.
The message can be used even to indicate th e risk of damage t o the machine
only.

• This wor d is used when precautions are indicated, which must be taken to avoid

actions that may shorten the life of the machine.

DANGER

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

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

DANGER

• To make the information clearer, some illustrations in this manual represent the machine without safety

guards. Do not use the machine without guar ds and do not start the engine when the engine pr ot ection
casing is open, if this is not expressly prescribed for some specific maintenance operations.

2

INFORMATION ON SAFETY

DANGER

DANGER

DANGER

DANGER

• It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu Utility can-

not be held liable for any damage to persons, property or the machine, if this has been tampered with
by modifying the standard setting of the hydraulic system.

• Before carrying out any electrical welding, disconnect the battery, the alternator and the connector of

the gearshift unit installed under the steering wheel (see “2.8.13 PRECAUTIONS CONCERNING THE
BATTERY AND THE ALTERNATOR” - “2.8.15 PRECAUTIONS CONCERNING THE GEARSHIFT”).

• Install only authorized additional equipment (see “6.1 AUTHORIZED OPTIONAL EQUIPMENT”).

• The machine can travel on roads only if provided with homologated equipment; before travelling on

roads, make sure that the equipment with which the machine is provided is homologated and that the
safety locks are correctly connected.

3

INTRODUCTION

IMPORTANT

☞

1.3 INTRODUCTION

1.3.1 INTENDED USES

The Komatsu Utility BACKHOE LOADERS d escr ibed i n this manual have been desig ned and constr ucted to be
used mainly for the following functions:

• LOADER

• EXCAVA TOR

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

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

• SNOWPLOUGH (ANGLEDOZER BLADE - SNOWPLOUGH)

• DEMOLITION (HAND HAMMER - HAMMER ON THE BACKHOE)

• DITCH CLEANING AND DIGGING (SPECIAL BUCKETS)

1.3.2 IMPROPER OR UNAUTHORIZED USES

CAUTION

• This paragraph describes some of the improper or unauthorized uses of the machine; since it is impos-

sible to predict all the possible improper uses, if the machine happens to be used f or particular applica­tions, contact your Komatsu Utility Dealer before carrying out the work.

• The instructions regarding the authorized optional equipment are given in the relevant operation and

maintenance manuals; if the equipment is supplied by Komatsu Utility, these publications are enclosed
to this manual.

• The instructions regarding the assembly of the authorized equipment, the controls requiring special ar-

rangement on the machine and the hydraulic couplings necessary for the operation of the equipment
are grouped in the final section of this manual.

Komatsu Utility backhoe loaders are constr ucted exclusively for the handling, excavation and treatment of iner t
materials; therefore, the following uses are absolutely forbidden:

• USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS.

• USE OF THE MACHINE FOR LIFTING PERSONS OR OBJECTS.

• TRANSPORTATION OF PERSONS even if they are in the operator’s cab.

• TRANSPORTATION OF CONTAINERS with fluids, flammable fluids, loose material, without the approp riate

slinging equipment.

• TRANSPORTATION AND L IFTING (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.

• USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.

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

• USE OF THE MACHINE FOR LIFTING DAMAGED VEHICLES.

4

INTRODUCTION

IMPORTANT

☞

1.3.3 MAIN CHARACTERISTICS

• Simple and easy operation.

• Servo-assisted steering with priority hydraulic system.

• Three steering modes that can be selected with a push button:

- Two-wheel steering

- All-wheel steering

- Crab steering

• Gearshift with elec tronic gear selection through soleno id valve actuators and t ransmission wi th hydraulic con-

verter; reversal and gear shifting with controls on a single lever.

• Loader control through a single lever ensuring also combined movements that can be modulated proportionally

and continually.

• Backhoe controls with two levers ensuring also combined movements that can be modulated proportionally and

continually.

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

• Separate accelerator controls for the two operating positions.

• Foot brake control.

• Easy maintenance with simplified intervals.

• Automatic engagement and disconnection of the differential locking on both axles (front and rear).

1.3.4 RUNNING-IN

Every machine is scrupulously adjusted and tested before delivery.
A new machine, however, must be used car efully for the fir st 100 hours, in order to en sure prop er runni ng-in of
the various components.
If the machine is subj ected to excessive work loa d at the beginni ng of operation, its potential yiel d and its func­tionality will be shortly and untimely reduced.
Every new machine must be used carefully, paying special attention to the following indications:

• After the star t, let the engine idl e for 5 minutes, in such a way as to warm it up gradually before actual opera-

tion.

• Avoid operating the machine with the limit loads allowed or at high speed.

• Avoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals.

• After the first 250 hours, carr y out the following operations, in addition to thos e 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 oil in the final reduction gears (front and rear axle).
4 - Check and adjust the engine valve clearance.
5 - Change the hydraulic circuit oil filter.

SYNTHETIC BIODEGRADABLE OIL TYPE HEES

On machines in whic h t he s y nthe tic bi ode gradable oil ty pe HEE S is us ed, the following ope rations ar e t o be per ­formed besides the standard maintenance operations:

• After the first 50 hours of operation, change the hydraulic circuit drain filter.

• After the first 500 hours of operation, change the hydraulic circuit oil.

• When changing the oil filters (cartridges), check their innner part to make sure that there are no depos-

its.
If considerable deposits are observed, find out what may have caused them before starting the ma­chine.

• The number of operation hours is indicated by the hour meter, while the par tial service hours for the

various maintenance operations to be carried out on the machine are stored and displayed on the elec­tronic screen positioned on the front dashboard.

5

PRODUCT IDENTIFICATION

1.4 PRODUCT IDENTIFICATION

The Komatsu Utility backhoe loader a nd its main com ponents are identifi ed by serial numbers s tamped 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 SERIAL NUMBER

The machine ser ial number is stampe d on the front par t of the
main frame, on the right side.

RWAB0070

1.4.2 MACHINE IDENTIFICATION PLATE

The Komatsu Utility backhoe loader s described in this manual
are provided with the CE mar k, which certifies th at they are in
compliance with the CE harmonized standards.
The plate with the mark is appl ied inside the operator’s cab, on
the left vertical wall of the frame, in correspondence with the
brake pedals.

RWA04680

MODELLO - MODEL
TYP - MODELE

MATRICOLA N˚ - SERIAL N˚
FABR. NR. - SERIE NR.

ANNO - YEAR
BAUJAHR - ANNEE

MASSA TOTALE MAX - TOTAL MAX WEIGHT
ZUL. GESAMTGEWICHT - POIDS TOTAL MAX

POTENZA MOTORE - ENGINE POWER
LEISTUNG - PUISSANCE MOTEUR

MASSA MAX ASSE ANT. - MAX WEIGHT FRONT AXLE
ZUL. ACHSLAST VORN - POIDS MAX ESSIEU AV

MASSA MAX ASSE POST. - MAX WEIGHT REAR AXLE
ZUL. ACHSLAST HINTEN - POIDS MAX ESSIEU AR

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

kg

kw

kg

kg

21D-98-12580

RWA34270

MODEL

SERIAL N

YEAR

TOTAL MAX WEIGHT

ENGINE POWER

MAX WEIGHT FRONT AXLE

MAX WEIGHT REAR AXLE

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

kg

kw

kg

kg

6

1.4.3 ENGINE SERIAL NUMBER AND EX­HAUST GAS EMISSION PLATE

The engine serial number is stam ped on the pl ate posi tioned on
the rear side of the tappet cover.

The plate regardin g the exhaust emission r egulations is applied
to the front side of the tappet cover.

PRODUCT IDENTIFICATION

RWAB0480

1.4.4 FRONT AXLE SERIAL NUMBER

The serial number of the fro nt axle is st amp ed on the plate posi­tioned on the right side of the axle body.

1.4.5 REAR AXLE SERIAL NUMBER

The serial number o f the rear axle i s sta mped on the pl ate pos i­tioned on the left side of the axle body.

RWAB0620

RWAA8910

RWAA8920

7

PRODUCT IDENTIFICATION

1.4.6 TRANSMISSION SERIAL NUMBER

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

RWA02540

1.4.7 CAB SERIAL NUMBER

The cab serial number is stamped on the plate positioned on the
right center pillar.

1.4.8 CANOPY SERIAL NUMBER (if provided)

The serial number is stam ped on the plate po sitioned inside the
canopy, on the front right part.

RWA02500

RWA18190

8

1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS

Machine n. Model
Engine n.
Front axle n.
Rear axle n.
Transmission n.
Cab n.
Canopy n.

Dealer:

PRODUCT IDENTIFICATION

Address:

Person to contact:

NOTES:

Tel.

9

THIS PAGE WAS INTENTIONALLY LEFT EMPTY

10

TABLE OF CONTENTS

Page

TABLE OF CONTENTS

1.1 FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 INFORMATION ON SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3.1 INTENDED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3.2 IMPROPER OR UNAUTHORIZED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

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

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

1.4.1 MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4.2 MACHINE IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE. . . . . . . . . . . . . . . . . 7

1.4.4 FRONT AXLE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.4.5 REAR AXLE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4.6 TRANSMISSION SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4.7 CAB SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4.8 CANOPY SERIAL NUMBER (if provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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 . . . . . . . . . . . . . . . . . . . . 26

2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED . . . . . . . . . . . . . . . . . . . . . . . 27

2.2 GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2.1 GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2.2 SAFETY DEVICES AND GUARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2.4 UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.2.5 LEAVING THE OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.2.6 GETTING ON AND OFF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.2.7 CHECKING THE REAR-VIEW MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.2.9 PREVENTING BURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER. . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . 32

2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . 33

2.3.1 SAFETY ON THE WORK SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.3.2 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB. . . . . . . . . . . . . . . . . . . . . . 33

2.3.4 ROOM VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD

WIPER BLADES AND THE BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

11

TABLE OF CONTENTS

Page

2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.4.1 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.4.2 RULES FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.4.3 CHECKS FOR TRAVELLING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.4.4 MOVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.4.5 WORKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.4.6 PREVENTING ELECTROCUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.4.7 VISIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT. . . . . . . . . . . . . . . . . . . . 39

2.4.10 WORKING ON LOOSE GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.4.11 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.5.1 LOADING AND UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.5.2 THE ROUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.6 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.6.2 STARTING WITH BOOSTER CABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.7 PRECAUTIONS FOR EMERGENCY RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.8.1 WARNING PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.8.2 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.8.3 PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.8.4 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.8.5 WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.8.6 KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.8.7 USE OF THE ENGINE DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY . . . . . . . . . 46

2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION

OR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.8.10 RULES FOR REFUELLING AND ADDING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.8.12 USING LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR . . . . . . . . . . . . 49

2.8.14 PRECAUTIONS CONCERNING THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

2.8.15 PRECAUTIONS CONCERNING THE GEARSHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.8.16 HANDLING HIGH-PRESSURE PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.8.17 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL . . . . . . . . . . . 50

2.8.18 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES

AND PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.8.19 COOLING FAN AND FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.8.20 WASTE MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.8.21 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES . . . . . . . . . . . . . . . . . . . . . . . . 52

2.8.22 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE. . . . . 52

2.8.23 PRECAU TIONS FOR THE USE OF THE SYNTHE TIC BIODEGRADABLE OIL

TYPE HEES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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DESCRIPTION AND USE OF THE MACHINE

3.1 SAFETY LOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.1.1 FRONT LOADER LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.1.2 BACKHOE LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.2 GENERAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.2.1 FRONT GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.2.2 BACKHOE GENERAL VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

3.2.3 CAB INSIDE GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.2.3.1 CAB INSIDE GENERAL VIEW (Standard version) . . . . . . . . . . . . . . . . . . . . . . 61

3.2.3.2 CAB INSIDE GENERAL VIEW (Version with servcontrols available on request) 62

3.3 INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.3.1 FRONT INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.3.2 SIDE INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.3.2.1 SIDE INSTRUMENTS (Standard version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.3.2.2 SIDE INSTRUMENTS (Version with servo controls available on request) . . . . . 76

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

3.3.4 ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

3.3.5 MACHINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.3.5.1 MACHINE CONTROLS (Standard version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.3.5.2 MACHINE CONTROLS (Version with servo controls available upon request) . . 87

3.4 FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

3.4.1 EQUIPMENT FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

3.4.1.1 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

3.4.1.2 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

3.4.2 ENGINE LINE FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

3.4.2.1 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

3.4.2.2 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

3.4.3 SIDE DASHBOARD RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

3.4.4 SIDE DASHBOARD RELAYS AND FUSES (Only with servo controls) . . . . . . . . . . . . . . . . 131

3.4.4.1 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

3.4.4.2 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

3.5 GUARDS, CAB AND DRIVER’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

3.5.1 ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

3.5.2 CANOPY (if provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

3.5.3 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

3.5.4 VENTILATION AND HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

3.5.5 AIR CONDITIONER (if installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

3.5.6 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

3.5.6.1 SEAT (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

3.5.6.2 SEAT (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

3.5.7 SAFETY BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

3.5.8 FIRE EXTINGUISHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

3.5.9 FIRST AID KIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

3.5.10 TECHNICAL DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

3.5.11 ADDITIONAL TOOL BOX (if provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

3.6 USE OF THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3.6.1 CHECKS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3.6.1.1 VISUAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3.6.1.2 DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3.6.1.3 OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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3.6.2 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES . . . . . . . . 145

3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES . . . . . . . . . . . . . . . 146

3.6.3 WARMING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

3.6.4 HEATING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

3.6.5 HOW TO MOVE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

3.6.5.1 ENGAGING THE FOUR-WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

3.6.5.2 MOVING ON SLOPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

3.6.5.3 MAXIMUM IMMERSION DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

3.7 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

3.7.1 PARKING ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

3.7.2 PARKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

3.8 STOPPING THE ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

3.9.1 LOADING AND UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

3.9.2 TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

3.10.1 FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

3.10.2 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

3.10.3 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

3.10.4 OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . 158

3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

3.12 USING THE MACHINE AS A LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

3.12.1 BUCKET POSITION INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

3.12.2 ORGANIZING THE WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

3.12.2.2 LOADING OPERATIONS ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

3.12.3 CHANGING THE STANDARD FRONT BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

3.13 USING THE MACHINE AS AN EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT. . . . . 163

3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 164

3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

3.13.4 DIGGING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

3.13.5 CHANGING THE BACKHOE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

3.14 LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

3.14.1 BEFORE THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

3.14.2 DURING THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

3.14.3 AFTER THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

3.15 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

3.15.1 HOW TO REMOVE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

3.15.3 IF THE BATTERY IS DEPLETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

3.15.3.1 STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

3.15.4 OTHER TROUBLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

3.15.4.1 ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

3.15.4.2 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

3.15.4.3 BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

3.15.4.4 CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

3.15.4.5 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

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MAINTENANCE

4.1 GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4.2 MAINTENANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

4.2.1 NOTES REGARDING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

4.2.1.1 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

4.2.1.2 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

4.2.1.3 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

4.2.4 NOTES REGARDING LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING. . . . . . . . . . . . . . 183

4.3 FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS. . . . . . . . . . . . . . 186

4.4 DRIVING TORQUES FOR SCREWS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

4.4.1 STANDARD DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

4.4.2 SPECIFIC DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

4.5 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

4.5.1 LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks) . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

4.5.3 LUBRICATION DIAGRAM (Front bucket rapid couplings) . . . . . . . . . . . . . . . . . . . . . . . . . . 190

4.5.4 LUBRICATION DIAGRAM (Telescopic arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

4.5.5 LUBRICATION DIAGRAM (Offset device). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY . . . . . . . . . . . . . . 193

4.6.1 CRITICAL PARTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

4.7 MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

4.7.1 WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE . . 202

4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER . . . . . . . . . . . . . . . . . . . . . 203

4.7.1.c CHECKING AND CLEANING THE RECIRCULATING AIR FILTER

(only for machines with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

4.7.1.d BLEEDING THE BRAKING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

4.7.1.e CLEANING THE WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

4.7.1.f CHECKING AND ADJUSTING THE WHEEL TOE-IN . . . . . . . . . . . . . . . . . . . . . 206

4.7.1.g CHECKING AND ADJUSTING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . 207

4.7.1.h CHECKING THE BRAKING EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

4.7.1.j CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE. . . . . . . . . . . . . . 209

4.7.1.k ADJUSTING THE AUTOMATIC RETURN-TO-DIG DEVICE

OF THE FRONT BUCKET (if installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

4.7.1.l CHECKING AND ADJUSTING THE STABILIZER SLACK . . . . . . . . . . . . . . . . . 210

4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER . . . . . . 211

4.7.2.a CHANGING THE HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

4.7.2.b CHANGING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

4.7.3 CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

4.7.3.a VARIOUS CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

4.7.3.b CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

4.7.3.c CHECKING THE FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

4.7.3.d CHECKING THE ENGINE OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

4.7.3.e CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL . . . . . . . . . . . . . . . . . . . . . 214

4.7.3.f DRAINING THE WATER SEPARATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

4.7.4.a LUBRICATING THE JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

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4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION

(Only for machines in which the synthetic biodegradable oil type HEES is used) . . . . . . . . . 218

4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

4.7.6.a CHECKING THE RADIATOR FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

4.7.6.b CHECKING THE BRAKING SYSTEM OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . 218

4.7.6.c LUBRICATING THE PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

4.7.6.d LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING

AND THE REAR AXLE JOINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

4.7.6.e CHECKING THE TYRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

4.7.6.f CHECKING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

4.7.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . 222

4.7.8 MAINTENANCE EVERY 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

4.7.8.a ADJUSTING THE FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

4.7.8.b ADJUSTING THE A/C COMPRESSOR BELT TENSION

(Only for machines with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

4.7.8.c CHECKING THE BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . 225

4.7.8.d CHECKING THE FRONT AXLE OIL LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

4.7.8.e CHECKING THE REAR AXLE OIL LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

4.7.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL . . . . . . . . . . . . . . . 227

4.7.8.g CHECKING THE WHEEL NUT DRIVING TORQUE . . . . . . . . . . . . . . . . . . . . . . 227

4.7.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION

(Only for machines in which the synthetic biodegradable oil type HEES is used) . . . . . . . . . 228

4.7.10 MAINTENANCE EVERY 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

4.7.10.a CHANGING THE ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

4.7.10.b CHANGING THE ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

4.7.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER . . . . . . . . . . . . . . . . . . . . 230

4.7.10.d CHANGING THE FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

4.7.10.e DRAINING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

4.7.10.f DRAINING THE HYDRAULIC OIL TANK

(Only for machines in which the synthetic biodegradable oil type HEES is used) 235

4.7.10.g CLEANING THE OUTSIDE OF THE RADIATORS . . . . . . . . . . . . . . . . . . . . . . . 236

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

(Only for machines with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

4.7.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 238

4.7.11.a CHANGING THE FRONT AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

4.7.11.b CHANGING THE REAR AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

4.7.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL . . . . . . . . . . . . . . . . . . . . . 240

4.7.11.d CHANGING THE HYDRAULIC TRANSMISSION FILTER. . . . . . . . . . . . . . . . . . 241

4.7.11.e CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE . . . . . . . . . 241

4.7.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 242

4.7.12.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION

FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

4.7.12.b CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

4.7.12.c CHANGING THE BRAKING SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

4.7.12.d CHECKING THE ALTERNATOR AND THE STARTER . . . . . . . . . . . . . . . . . . . 246

4.7.12.e CHECKING THE QUANTITY OF COOLANT IN THE A/C SYSTEM

(Only for machines with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

4.7.13 MAINTENANCE EVERY 4000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 248

4.7.13.a CHANGING THE A/C DEHYDRATING FILTER

(Only for machines with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

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

(Only for machines with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

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TECHNICAL SPECIFICATIONS

5.1 TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

5.1.1 STANDARD OVERALL DIMENSIONS WITH CENTERED BACKHOE . . . . . . . . . . . . . . . . 250

5.1.2 STANDARD OVERALL DIMENSIONS WITH FOLDED BACKHOE . . . . . . . . . . . . . . . . . . 250

5.1.3 TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

5.1.4 LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

5.1.4.1 SYMBOL TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

5.1.4.2 LIFTING CAPACITY (STANDARD BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

5.1.4.3 LIFTING CAPACITY (OFFSET BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

AUTHORIZED OPTIONAL EQUIPMENT

6.1 AUTHORIZED OPTIONAL EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

6.1.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

6.2 FRONT EQUIPMENT QUICK COUPLING DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

6.2.1 MANUAL CONTROL QUICK COUPLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

6.2.2 HYDRAULIC CONTROL QUICK COUPLING FOR STANDARD BUCKET. . . . . . . . . . . . . . 258

6.2.3 HYDRAULIC CONTROL QUICK COUPLING FOR 4IN1 BUCKET AND OPTIONAL

EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

6.3 4in1 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

6.3.1 DESCRIPTION AND CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

6.3.2 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

6.3.3 INSTALLING THE 4in1 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

6.3.4 USING THE 4in1 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

6.3.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

6.4 PALLET FORKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

6.4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

6.4.2 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

6.4.3 USING THE FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

6.4.3.1 PREPARING THE PALLET FORKS FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . 263

6.4.3.2 OVERTURNING THE FORKS FOR TRAVEL ON ROADS . . . . . . . . . . . . . . . . . 264

6.4.4 REMOVING THE FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

6.4.5 INSTALLING THE FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

6.4.6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

6.5 BACKHOE TELESCOPIC ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

6.5.1 DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

6.5.1.1 VERSION WITH STANDARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

6.5.1.2 VERSION WITH SERVO CONTROLS (if installed) . . . . . . . . . . . . . . . . . . . . . . . 266

6.5.2 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

6.5.3 USING THE TELESCOPIC ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

6.5.4 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

6.5.4.1 ADJUSTING THE GUIDE SLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

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6.6 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER . . . . . . . . . . . . . . 270

6.6.1 DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

6.6.1.1 VERSION WITH STANDARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

6.6.1.2 VERSION WITH SERVO CONTROLS (if installed) . . . . . . . . . . . . . . . . . . . . . . 270

6.6.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED. . . . . . . . . . . . . . 271

6.6.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER . . . . . . . . . . . . . . . . . . . . . . 275

6.6.3.1 INSTALLING THE HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

6.6.3.2 REMOVING THE HAMMER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

6.6.4 USING THE HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

6.6.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

6.7 APPLICATION OF THE OFFSET DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

6.7.1 DESCRIPTION AND CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

6.7.1.1 VERSION WITH STANDARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

6.7.1.2 VERSION WITH SERVO CONTROLS (if installed) . . . . . . . . . . . . . . . . . . . . . . 279

6.7.2 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

6.8 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL

OIL FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

6.8.1 DESCRIPTION AND CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

6.8.1.1 VERSION WITH STANDARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

6.8.1.2 VERSION WITH SERVO CONTROLS (if installed) . . . . . . . . . . . . . . . . . . . . . . 280

6.8.2 INSTALLING AND CONNECTING THE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

6.8.3 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

6.9 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET . . . . . . . . . . . . . . . 282

6.9.1 DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

6.9.1.1 VERSION WITH STANDARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

6.9.1.2 VERSION WITH SERVO CONTROLS (if installed) . . . . . . . . . . . . . . . . . . . . . . 283

6.9.2 INSTALLING THE CLAMSHELL BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

6.9.3 USING THE CLAMSHELL BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

6.9.4 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

6.10 ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER . . . . . . . 286

6.10.1 DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

6.10.2 CONNECTING AND REMOVING THE HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

6.10.2.1 CONNECTING THE HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

6.10.2.2 REMOVING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

6.10.3 USING THE HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

6.10.4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

6.11 LOAD STABILIZER SYSTEM (LSS) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

6.11.1 ACCUMULATOR OF THE LOAD STABILIZER SYSTEM (LSS) . . . . . . . . . . . . . . . . . . . . . 289

6.12 REAR EQUIPMENT RAPID COUPLING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

6.12.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 291

6.12.2 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

18

SAFETY AND
ACCIDENT PREVENTION

SAFETY, NOISE AND VIBRATION PLATES

2.1 SAFETY, NOISE AND VIBRATION PLATES

2.1.1 POSITION OF THE SAFETY PLATES

• 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.

• If the plates are damaged, ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer.

• In case of replacement of a component provided with a safety plate, make sure that this plate is applied also on

the new piece.

• The machine can be p rovided with other pla tes in addition to those indicated below; keep also to the instr uc-

tions given in the additional plates, in any case.

RWA26140

RWA00020

20

RWA00010

RWA00020

RWA26150

SAFETY, NOISE AND VIBRATION PLATES

RWA00030

RWA00020

RWA00150

RWA00190

RWA00020

RWA00160

RWA37700

21

SAFETY, NOISE AND VIBRATION PLATES

2.1.2 PICTOGRAMS AND RELEVANT MEANINGS

The warning and danger plates applied onto the machine are accompanied or represented by pictograms.
The personnel in charge with the operation and maintenance of the machine must know the symbols contained in
the pictograms perfectly; the following description illustrates what they look like and their respective meanings.

DANGER IN THE WORK AREA

• Do not approach or stand in the equ ipment operating radius

when the boom and the bucket are raised.

RWA00020

DO NOT OPEN THE HOOD

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

FILLING THE HYDRAULIC SYSTEM WITH
OIL

(Only for machines in which the synthetic biod egr adable oil
type HEES is used)

O VERTURNING THE FORKS

• When the forks are overturned for use or storage, be care-

ful to the grasping points, since hands and feet may be in­jured and even cut.

BIO-OIL

RWA00010

RWA34380

22

RWA35830

CONSULT THE MANUAL

• Carefully read the contents of the manual before using the ma-

chine or performing maintenance operations.

HYDRAULIC OIL TOPPING UP

SAFETY, NOISE AND VIBRATION PLATES

RWA00030

REFUELLING

ENGINE LUBRICATING OIL FILTER

FUEL FILTER

RWA00050

D

RWA00040

RWA00080

D

ENGINE AIR SUCTION FILTER

RWA00060

RWA00090

23

SAFETY, NOISE AND VIBRATION PLATES

ENGINE COOLANT

ENGINE COOLANT PRESSURE

HYDRAULIC OIL LEVEL

RWA00130

RWA00110

HYDRAULIC OIL FILTER

ELECTRIC OUTLET

TRANSMISSION OIL LEVEL

RWA00120

RWA00100

RWA00070

12 V

HYDRAULIC TRANSMISSION OIL FILTER

24

RWA00180

RWA00170

ANCHORAGE POINT

EMERGENCY EXIT

BOOM LOCK

SAFETY, NOISE AND VIBRATION PLATES

RWA00200

RWA00190

SWING LOCK

BRAKE OIL

DO NOT LIFT MORE THAN 1000 kg

RWA00160

RWA00150

RWA00140

> 1000 Kg

RWA00210

25

SAFETY, NOISE AND VIBRATION PLATES

2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB

• 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.

• If the plates are damaged, ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer.

• In case of replacement of a component provided with a noise plate, make sure that this plate is applied also on

the new piece.

ISO 6396

NOISE OUTSIDE THE CAB

• This value indicates the noise level outside the machine and

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

NOISE INSIDE THE CAB

• This value indicates the maximum noise level perceived by the

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

2000/14/EC

2000/14/EC

RWA37710

RWA37720

26

ISO 6396

RWA37730

SAFETY, NOISE AND VIBRATION PLATES

2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED

• According to the res ults of the test s carried out t o determine the vibrations transmi tted to the operator by the

machine, the upper limbs are subjected to vibrations lower than 2.5 m/sq.sec., while the seated part of the body
is subject to vibrations lower than 0.5 m/sq.sec.

27

GENERAL PRECAUTIONS

2.2 GENERAL PRECAUTIONS

2.2.1 GENERAL SAFETY RULES

• Only trained and authorized personnel can use the machine and perform maintenance operations.

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

erations.

• When working with other op erators or w hen the wor k site is often occup ied by other op erators, make sure that

everyone knows and understands all t he signals described above and, in any cas e, 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

• Make sure that all the g uards and covers are in the correct posit ion. Have guards and covers chang ed or re-

paired if damaged. Neither use the machine without guards, nor rem ove the guards when the engine is run­ning.

• Always use the proper safety devices to lock the machine when parking and fasten the safety belt.

• For the safety devices, see “3.1 SAFETY LOCKS”.

• For the safety belt, see “3.5.7 SAFETY BELT”.

• Do not remove the safety devices and always keep them in good operating conditions.

• Any improper use of the safety devices may result in serious injuries or even death.

2.2.3 CLOTHING AND PERSONAL PRO-

TECTION ITEMS

• Do not wear large or loos e clothes, ri ngs and watches and d o

not approach the machi ne with lo ose long h air, since they can
get entagled in the moving parts of the machine and cause se­rious injuries or damage.
Avoid also wearing clothes dir ty with oi l or fuel, since they are
flammable.

• Wear a hard hat, goggles, safety shoes, mask, gloves and

headphones when ope rating the m achine or pe rforming main­tenance operations.

• 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 pi ns with a hammer and when blowing
compressed air into the air filter and the radiator to clean them.
During these opera tions, make also sure that no one i s sta nd­ing or working near the machine without the necessary protec­tions.

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

dBA, it is necessar y to use headphones or ear plu gs and be
particularly careful, especially at the end of the work shift.

28

RWA00960

GENERAL PRECAUTIONS

IMPORTANT

☞

2.2.4 UNAUTHORIZED MODIFICATIONS

• Any modification made without the authorization of Komatsu Utility can involve hazards.

• Before making a modification, consul t your Komatsu Utility Dealer. Komatsu Utility declines any respo nsibility

for injuries or damage caused by unauthorized modifications.

2.2.5 LEAVING THE OPERATOR’S SEAT

• When leaving the operator’s seat, even if temporarily, make

sure that t h e m ac h ine is in a safe positio n. (See “2.4.11 PARK­ING THE MACHINE”).

• Before leaving the operator’s seat, carry out the following oper-

ations in the sequence indicated below:
1 - Rest the equipment onto the ground.
2 - Connect the safety devices of the controls.
3 - Apply the parking brake.
4 - Shift the reversing gear lever to the neutral position.
5 - Stop the engine.

RWA31250

• If the machine is equipped with backhoe servo controls,

before leaving the operator seat always engage the con­trol locking safety device by pressing the relevant switch,
see “3.3.5.2 MACHINE CONTROLS (Version with servo
controls)”, pos. 26.

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

RWA34810

RWA35030

29

GENERAL PRECAUTIONS

2.2.6 GETTING ON AND OFF THE MA-

CHINE

• Do not jump on or off the machine, either when it is at rest and

when it is moving.

• When getting on or off the ma chine, always use the handles

and the safety ladders; get on and off t he machine very care­fully.

• Never hold or rest on the steering wheel or the gearshift lever.

• Either when getting on and when get ting off the machine, al-

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

• Tighten the handle and ladder connect ion screws if they are

loose and clean the handl es 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.

The cab

RWA25650

Safety canopy

2.2.7 CHECKING THE REAR-VIEW MIR-

RORS

• Make sure that the rear-view mirrors are clean and correcly

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

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

the machine immediately and fasten or change them.

• Working without checking the back of the machi ne is danger-

ous, since the machine may hit persons who are in cautiously
standing in the wor k area, fixed obstacl es or manoeu vring ve­hicles.

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 par ticularly flammable
and therefore extremely hazardous.

• Keep any naked flame away from flammable fluids.

• Stop the engine and do not smoke when refuelling.

• Top up with fu el and oil only after stopping the engine and in

well ventilated areas.

• Top up wi th fuel an d oil in a well deli mited area a nd do not al-

low unauthorized persons to approach.

RWA25760

RWA25860

RWA00970

30

• When refuelling, hold the fuel gun firmly and keep it constantly

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

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

• Do not fill the tank completely, in order to leave room for the fu-

el to expand.

• In case some fuel is spilled, wipe it up immediately.

2.2.9 PREVENTING BURNS

• If the engine coolant, the engi ne oil and the hydraulic oil are

hot, use heavy cloths and wear gloves, heavy clothing and
safety goggles before carryi ng out any check or touching the
hot parts.

• Before checking the coolant level, stop the en gine and let the

fluid cool down.
If a check is necessary du e to the overheating of the engine,
slowly loosen the radia tor plug to release any residual pres­sure before removing it. The hot fluid that spurts out may
cause serious burns.

• Before checking the engine oil and hydraulic circuit oil level,

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

GENERAL PRECAUTIONS

RWA00980

RWA00990

2.2.10 PREVENTING DAMAGE DUE TO AS­BESTOS POWDER

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

haled.

• If you handle materials contai ning asbes tos fib ers, keep to the

instructions given below:
1 - Do not use compressed air, b ut only aspirators to clean the

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

2 - Use low-pressure water to keep down the dust when clean-

ing.

3 - If there is danger that there may be asbestos powder in the

air, operate the machine with the wind to your back when­ever possible.

4 - Even if the cab provides suitable protection, use an ap-

proved and homologated respirator.

5 - The powder gathered during the cleaning operations must

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

RWA01000

RWA01010

31

GENERAL PRECAUTIONS

2.2.11 PREVENTING D AMAGE CA USED BY THE WORK EQUIPMENT

• Do not stand within or approach the operating radius of the

work equipment, even when the operator is on board th e ma­chine and the engine is running.

• Do not stand or work unde r the arms or the articul ati ons whe n

the arms are lifted, if you are not sure that the safety locks
have been duly engaged.

• Do not carry out any operation requiring the lifting of the arms,

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

2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT

• Make sure that fire extinguishers have been provided and

check their position.

• Periodically make sure that th e fire extinguishers are loaded

and that you know how to use them.

RWA01020

• Find out where the first aid kit has been located.

• Periodically make sure that the first aid kit conta ins the neces-

sary disinfectants, bandages, medicins, etc.

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

• Make sure that you have the phone numbers of the persons or

structures you may need to contact in case of an emergency at
hand (either at the wor k site and where maintenance opera­tions are performed).

RWA01030

2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE

• If the cab is inadvertently hit or the machine overturns during work, the cab may be damaged with cons eq uen t

reduction of its stiffness and of the safety that must be guaranteed to the operator (Rops/Fops homologation).
Contact Komatsu Utility or an Authorized Komatsu Utility Dealer to have the cab structure and resistance
checked in case of impact or damage.

2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT

• When installing and using optional equipment, carefully read the relevant instruction manual and keep to the in-

dications given therein.

• Do not use optional o r special equipment without the authorization of Komatsu Utility or th e Komatsu Utility

Dealer.
The installation and us e of unauthori zed equipment may create safety problems and ad versely affect the effi­ciency and life of the machine.

• Komatsu Utility cannot be held li able for any injury, accident, product failure resulting fr om the installa tion and

use of unauthorized equipment.

32

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

• Before starting the engine, thoroughly check the area for any

unusual condition of the ground due to which work may be
dangerous.

• Check the conditions of the ground at the work site an d before

starting the engine defin e the work pl an and the best and s af­est operating procedure.

• Make the ground surface as level as possible before carr ying

out any operation.

• In case of work on the road, protect pedestr ians and cars by

designating a person for work site traffic duty and install fences
around the work site.

• If water lines, gas lines, and telephone or high-voltage electr i-

cal lines are locate d under the work si te, contact the relevant
utility company in order to find out their exact positions or to
make them inneffective until the end of the operations. Be
careful not to sever or damage any of these lines.

RWA00220

• Check the depth and flow of water before operating in water or

on river banks.

2.3.2 FIRE PREVENTION

• Completely remove all wood chips, r ubbish, paper and other

flammable materials that may hav e accumulated inside the en­gine compartment, since they can cause fires.

• Check the fuel and hydraulic system pipes for leaks and if nec-

essary repa ir them. Wipe up any excess oil, fuel or other flam­mable fluids.

• Make sure that fire extinguish ers are available in the work a r-

ea.

RWA01040

2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR’S CAB

• Do not leave objects or tools lying a round in the operator ’s cab. They may hinder the operation of the brakes

and cause serious accidents.

• Keep the cab floor and the controls (steer in g wheel and levers) clean, by removing a ny trace of oil an d grease

and, as far as the floor is concerned, remove any excess dirt (earth, stones, etc.).

• Check the safety belt and change it if it is broken or damaged. Replace any component only wi th h omo log ated

parts available at Komatsu Utility or its Dealers.

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

33

PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE

2.3.4 ROOM VENTILATION

• 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

• Remove any trace of dirt from the cab windows, lights and rear-view mirrors, in order to ensure perfect visibility.

• Adjust the rear-vi ew mirrors if they have moved, so that the operat or sitting in t he driving position can c learly

see the back of the machine.
If any window, light or mirror is damaged, change it.

• Make sure that the road lights, stoplights, direction indicators and working lights are properly working. If neces-

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

• Check the conditions of the windshield wipe r blades; the scraping wire must be smooth, with no indent ations

and attached to the rubber back of the blade.
In case of doubts on the efficiency of the scraping wire, change the blades.

34

PRECAUTIONS TO BE TAKEN WHEN WORKING

IMPORTANT

☞

IMPORTANT

☞

2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING

2.4.1 STARTING THE ENGINE

• Before getting on the machine, walk around it and check for people and objects that might be in the way.

• Do not start the engine if warning plates have been attached to the steering wheel or the control levers.

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

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

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

2.4.2 RULES FOR ROAD TRAVEL

• The machine is equipp ed with multifunction safety locks that must b e used both for maintenance ope rations

and road travel.

• 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 raised from the ground, thus ensuring better

visibility and the stability of the machine.
2 - Install the front bucket antirotation lock and secure it with the safety pins.
3 - Install the teeth protection casing on the front bucket.
4 - Raise the backhoe boom until engaging the s afety coupl in g. The arm and bucket must in any case be com-

pletely folded.
5 - The backhoe must be rotated and resting on the str ucture. This is the onl y position homologat ed for road

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

wards the road center, against the lock and with the bucket facing the road side.
7 - Fasten the backhoe with the antirotation pin.
8 - Connect the safety chains to prevent the accidental lowering of the stabilizers.
9 - Engage the loader and backhoe control lever safety locks.

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

• If the machine is equipped with backhoe servo controls, before travelling on roads always engage the

control locking safety device by pressing the relevant switch, see “3.3.5.2 MACHINE CONTROLS (Ver­sion with servo controls)”, pos. 26.

• 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.

• When travelling on roads, keep to the rule of the road and operate the flashing light posi tioned on top of the

cab.

• When travelling on roads, keep the working lights off.

• When travelling on roads, use only the two-wheel steering moderuote.

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

35

PRECAUTIONS TO BE TAKEN WHEN WORKING

2.4.3 CHECKS FOR TRAVELLING IN RE­VERSE

• When operating in ar eas that m ay be hazardous or have poor

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

• Before moving the machine, sound t he horn to warn the per-

sons standing or working in the area.

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

seen through the rear -view mirrors and where someon e may
be standing.
It is necessar y to make sure that there is no one behind th e
machine before travelling in reverse.
On request the machine may be equipped with an acoustic
alarm (1) to be used in case of reversal. If the machine is
equipped with this acoustic alarm (1), before any reversal
make sure that it functions correctly.
See “3.3.5 pos. 1 REVE RSING GEAR LEVER” to check the
functionality of the alarm.

RWA25860

1

2.4.4 MOVING THE MACHINE

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

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

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

avoid moving it abruptly; sudden mano euvres cha nge the a tti­tude of the machine and make driving difficult.

• When travelling on rough ground, keep the speed low and

avoid sudden movements of the bucket arm.

RWAB0630

RWA25870

30÷40 cm

• If the machine has to travel over an obstacle, keep the front

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

36

PRECAUTIONS TO BE TAKEN WHEN WORKING

2.4.5 WORKING ON SLOPES

• Operations on slopes and on river or lake banks with damp

ground may result in the tipping over or slipping of th e ma­chine.

• Do not work with the bucket downward with respect to the trac-

tor.

• 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 advis able to go down or up to a flat
place to perform these operations.

• Do not travel on wet grass or thick layers of leaves: if the ma-

chine moves obliquely in these conditions, it may slip.

• Before working on a s lope, always check the efficienc y of the

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

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

the machine and cause serious injuries and even death.

• Avoid disengaging the gearshift with the push button posi-

tioned on the loader control lever.

• When travelling down a slope, engage a low gear, so that the

braking action of the engine is us ed to hold the machi ne, with
no need to strain the brakes.

RWA25880

20÷30 cm

WRONG

RWA25900

• When the fuel level indicator reaches the red reserve area dur-

ing work on a slope, immediately provide for refuelling; due to
the inclination of the ma chine, the engi ne may suck in air and
suddenly stop, which repr esents a grave risk for the safety of
the operator and of the persons before the machine.

• If the engine should s top all of a sudden, immediately lower

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

CORRECT

RWA26010

37

PRECAUTIONS TO BE TAKEN WHEN WORKING

2.4.6 PREVENTING ELECTROCUTION

• Digging operations near overhead electric lines are extremely

dangerous and they may also caus e death due to electrocu­tion; for this reason, when working near overhead electrical
lines always respect the minimum safety distanc es presc ribed
by the competent authorities and by the accident-prevention
rules in force.

• As far as underground long-distanc e lines are concer ned, the

minimum distance depends on the covering of the ducts in
which the cables are laid.

• The basic safety precautions to b e taken to prevent this risk

are the following:
1 - Wear shoes with thick rubber or leather soles.
2 - Request the aid of anoth er p er so n wh o ca n warn you if the

machine gets too close to the electric line.
3 - Operate at low speed.
4 - Learn what is to be done first in case of electrocution.
5 - Keep the phone number of the electr icity company and of

the nearest first aid station at hand.

• If the work equipme nt gets accidentally entangled in th e ca-

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

RWA04900

• When carrying out this kind of operations, warn everyone

standing in the work area to keep at the minimum distance
prescribed from the machine and the work equipment.

• Ask the electrici ty com pany what ar e the voltage of th e cables

and the minimum safety distance in advance.

DANGER

• The minimum distances from overhead lines can vary in the different countries, according to the cli-

mate 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 (min. 3 insulators) 5.5 m

38

66 kV (min. 6 insulators) 6 m
154 kV (min. 10 insulators) 8 m
275 kV (min. 19 insulators) 10 m

PRECAUTIONS TO BE TAKEN WHEN WORKING

2.4.7 VISIBILITY

• Switch on the road or working lights as soon as visibility decreases.

• If visibility decreas es due to mist, smoke or heavy rain, s top the machine in a safe position and wait for the

weather to improve until visibility becomes acceptable.

2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES

• If the ground is icy or covered with snow, the response of the m ac hin e to the movements of the ste er in g wh eel

may not be precise.
To limit the risks deriving from reduced directionality, 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 - Avoid any sudden braking, rapid acceleration and abrupt steering with reduced steering radius.

• If the machine is used to cl ear snow or as s nowplou gh o n r oad s ( in stall in g the specific optional equipmen t 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.).

2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT

• When working in tunnels, gall erie s, under ele ctri c cables or other duc ts (air, telephone lines) and wher ever the

height is limited, proceed with the greates t care to prevent the bucket or arms and th e backhoe bucket from
causing any damage.

2.4.10 WORKING ON LOOSE GROUND

• Avoid operating the machine too close to the edge of cliffs, overhangs and deep ditches.

These areas may collapse, mak ing th e machi ne fall down or tip over and this could resu lt in ser io us in jur ies or
death.
Remember that after heavy rain or earthquakes these dangerous conditions usually get worse.

• 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.

39

PRECAUTIONS TO BE TAKEN WHEN WORKING

IMPORTANT

☞

2.4.11 PARKING THE MACHINE

• Park the machine on firm and level ground. If this is not poss i-

ble and it is necessar y 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 stoppe d with the brakes, apply

the parking brake.

2 - Dump the front bucket to the unloadi ng 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 - Put wedges or safety blocks under the front and rear

wheels.

• Always rest the work equipment on th e ground; if it is neces-

sary to par k with ra ised ar ms, make sure that the s afety locks
are engaged.

• Always engage the control lever safety locks.

• If the machine is equipped with backhoe servo controls,

always engage the control locking safety device by press­ing the relevant switch, see “3.3.5.2 MACHINE CONTROLS
(Version with servo controls)”, pos. 26.

RWA26110

RWA26120

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

sure that the cab windows ar e closed, rem ove the ignition key
and finally lock the doors.

• If it is necessar y to par k on public roads, pr ovide for signall ing

the presence of the machine according to the local regulations
in force (signalling fires, fences, road works ahead, alt ernate d
direction and direction signs, etc.) .

RWA31250

40

RWA35030

RWA34810

TRANSPORTING THE MACHINE ON OTHER VEHICLES

CAUTION

2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES

2.5.1 LOADING AND UNLOA DING THE MACHINE

• Loading and unloadi ng the machine on/from a motor vehicle

always involves potential hazards. Proceed with extreme care.

• Perform loading and unloading on firm, level ground. Maintain

a safety distance from the edges of ditches or from road sides.

• If the vehicles used have not been appositely equipped, put

support blocks under the ramps, in order to avoid any bending.

• Always lock the wheels of the transpor ting vehicle with wedg-

es.

• Always use ramps that are sufficiently wide and can s upport

the weight of the machine. The lon gitudinal axes of the ramps
must be parallel to each other and perpendicular to the loading
side board and their di stance mus t be suitable for the tread of
the machine.

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

tened to the loading board and that they ha v e the same length.

Ramps

Max.15˚

Blocks

Blocks

RWA00240

• Position the ramps with a maximum inclination of 15°.

• Make sure that the ramp surface is clean an d th er e is no trace

of grease, oil, soil and ice; remove dir t fr om the wheel s before
starting to load the machine on the vehicle.

• The machine must be loaded on the vehicle with the bucket di-

rected forwards, that is, in the dire ction o f ad vancement of th e
vehicle.

• Do not correct the trajector y of the machine on the ramps. If

necessary, get down the ramps and start the operation again.

• After loading the machi ne, block its wheels with wedges and

secure it with tie-downs or chains that p revent even any side­ward shift (see “3.9 TRANSPORTING THE MACHINE ON
OTHER VEHICLES”).

2.5.2 THE ROUTE

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

• 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 o f the machine are compa tible with the road and any galler y, subway, bridg e,
electric and telephone lines, etc.

• Keep to the regulations in force regarding the permis sible width, height, weight of the machi ne and the trans-

port speed .

41

BATTERY

2.6 BATTERY

2.6.1 SAFETY PRECA UTIONS FOR WORK ON BATTERIES

• Electrolytic batteries contain sulphuric acid that can quickly

burn the skin and corrode clothes making holes in the fabric. If
you spill acid on yourself, immediately ri nse the involved area
with plenty of water.

• Battery acid may cause blindness if splashed into the eyes.

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

• If you accidentally swallow some acid, drink a large quant ity of

water or milk, beaten egg white or vegetable oil and in any
case antiacid substances like magnesia, bicarbonate, etc.;.
call a doctor or a poisoning prevention center immediately.

• When handling batteries, always wear safety goggles.

• Batteries generate hydrogen. Hydrogen is highly explosive

and can be easily ignited with small sparks or naked flames.

• Before working with batter ie s, sto p th e e ngi ne a nd remove the

ignition key.

• Avoid short-circuiting the batter y term inals through accidenta l

contact with metal objects or tools or through the inversion of
the terminals.

• Tighten the battery terminals securely. Loose terminals may

generate sparks and even cause the explosion of the battery.

RWA01060

WRONG

RWA01080

2.6.2 STARTING WITH BOOSTER CABLES

• When starting the machine with booster cables, always wear

safety goggles.

• When star tin g the en gin e by means of ano ther machi ne, avoid

any contact between the two machines.

• Be sure to connect the positive cable (+) first and then the neg-

ative or earth cable (-) when connecting the booster cables.
Disconnect first t he negative or earth (–) cable and then the
positive cable (+) after the start.

• Connect the batteries in parallel: positive to positive and nega-

tive to negative.

• When connecting the ea r th cable to the frame of the machin e

to be started, operate as far as possible from the battery.
(See "3.15.3 IF THE BATTERY IS DEPLETED").

• Do not attempt to star t the engine by causing a short-circuit

with the termina ls of the star ter ( see “2.8.14 PRECAUTIONS
REGARDING THE STARTER”).

42

RWA01180

RWA01190

PRECAUTIONS FOR EMERGENCY RECOVERY

CAUTION

2.7 PRECAUTIONS FOR EMERGENCY RECOVERY

• The draw hooks must be used only for the first ai d and not for

towing the machine.

• Before moving the machine, make sure that the gea r shift l ever

is in neutral and disengage the four-wheel drive.

• Incorrect manoeuvres may result in serious injuries or even

death.

• To move the machine, use prop erly dim ensioned steel cables;

do not use worn cables or cables with broken strands (A),
twisted cables (B), deformed cables (C).

• During the removal, no one can be allowed to get near the ma-

chines or the cable.

• Do not get astride the cable.

• Remove the machine only as much as necessary to permit the

required repairs.

• Do not remove the machine in any way other than that indicat-

ed in paragraph “3.15.1 HOW TO REMOVE THE MACHINE”.

F

RWA26130

• The maximum applicable force for each draw hook is

F = 6300 kg.

• Use cables having the same length and draw continuosly

and constantly, without jerks.

• 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.

F

RWA01930

RWA05380

43

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.1 WARNING PLATES

• Before starting any maintenance operation, position the ma-

chine on fir m and level ground, engage the safety locks either
for the equipment and the c ontrols, stop t he engine and apply
the parking brake.

• If another person starts th e engine and operates the controls

while the operator is p roviding for ser vice, this may result in
serious injuries or even death.

• To avoid these risks, alwa ys attach warning plates to the steer-

ing 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.

2.8.2 TOOLS

• Use only the tools provided with the machi ne and hi gh-quality

tools suitable for the tasks to be performed.

DO NOT

START

ENGINE

RWA01210

• Do not use worn, da maged, low-quality tools or tools that are

not suitable for the tasks to be performed, in order to avoid any
personal injury.

• After use, carefully clean th e tools and put them in the com-

partment obtained inside the seat support. If the operator
plans to keep on the machine som e tools whose dimensions
exceed those of the compar tment positioned under t he seat,
he can store them in an appropr i ate tool box positioned on the
rear outer part of the cab. See “3.5.11 ADDITIONAL TOOL
BOX (if provided).”

RWA01310

RWA02860

2.8.3 PERSONNEL

• Any maintenance opera tion must be carr ied out exclusively by author ized and duly trained per sonnel; s pecific

and personal prote ction me asur es must be ad opted w hen gr inding , weld ing an d when usin g sle dges or h eavy
hammers.

• When assemblying the equ ipment or cylinder connection pins, us e wooden, plastic or in any case not exces-

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

44

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.4 EQUIPMENT

• The normal or spec ia l equipment that must be instal le d o n th e

machine or that have been removed must be stored in safe
places, preventing them from falling down. If they fall on some­one, they can cause serious bodily harm.

• When assemblying or removing any equipment, make sure

that the ropes and the lifting h ook are in goo d conditions and
properly dimensioned for the load to be lifted.

2.8.5 WORKING UNDER THE MACHINE

• Always lower the work equipment to the ground or in a ny cas e

to their lowest position before performing service or repairs un­der the machine.

• Always lock the machine tyres securel y.

RWA01320

• Do not work under the mac hine, if this is not sufficiently s up-

ported.

2.8.6 KEEPING THE MACHINE CLEAN

• Spilled oil or grease, scattered tools or broken pieces are dan-

gerous, because they may cause someone to slip or t rip. Al­ways keep the machine and the work site clean and tidy.

• To clean th e machine, use a pressurized jet of warm water or

steam and the appropriate detergents available on the market.
Do not use gas oil, oil or solvents, since the former leave an
oily coat that favours the sticking of dust, whi le the la tter (even
if weak) damage the painted sur faces and therefore facilitate
rusting.

• While cleaning the machine, keep the pressurized jet at a min-

imum distance of approx. 60 cm in order not to dam age the
warning plates and the pictograms.
If the plates are damaged, request Komlatsu Utility or your
Komlatsu Utility Dealer to sen d you spare plates and chang e
them.

• Water into the electrical system provokes the oxidation of the

contacts and may hinder the start of the machine or even
make it start suddenly and abruptly. For this reason, never use
water or steam jets to cl ean sensor s, connecto rs or the ins ide
of the operator’s cab.

RWA02520

RWA01330

45

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

IMPORTANT

☞

2.8.7 USE OF THE ENGINE DURING MAINTENANCE

• During maintenanc e operations, let the en gine ru n only when indi spensable. If it is ne cessar y to have the en-

gine running (f or example, to wash the cooling circuit or to check the functionality of the alternator), an operator
should constantly remain in the cab, in order to be able to stop the engine whenever necessary.

• During maintenance operations with running engine, never move the control locking devices from the “lock” po-

sition or change the position of the gearshift lever.
Service personnel must not move any control lever.

• If the machine is equipped with backhoe servo controls, always engage the control locking safety de-

vice by pressing the relevant switch, see “3.3.5.2 MACHINE CONTROLS (Version with servo controls)”,
pos. 26.

• When carryin g out maintena nce operations, do no t touch the moving pa r ts of the mac hine and avoid wearing

large and loose clothes.

2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY

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

Fuel supply 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

• 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.

• If one of these parts is defective, change or repair it even if the change interval has not elapsed yet. (See “4.6

PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY).

46

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

IMPORTANT

☞

2.8.9 STOP THE ENGINE BEFORE CAR­RYING OUT ANY MAINTENANCE
OPERATION OR INSPECTION

• Stop the machine only o n firm and level ground and stop the

engine before carryi ng out any maintenance operation or in­spection.

• If it is necessary to have the engine running during mainte-

nance, engage the safety LOCKS of the equipment c ontrol le­vers, apply the parking brake and carr y out any maintenance
operation with the help of another person; an operator must re­main on board and the words to be used dur ing the operation
must be agreed upon.

• If the machine is equipped with backhoe servo controls,

always engage the control locking safety device by press­ing the relevant switch, see “3.3.5.2 MACHINE CONTROLS
(Version with servo controls)”, pos. 26.

RWA02000

• The person who carr ies out the maintenance operation must

be very careful not to touch any moving part of the engine.

RWA31250

RWA34810

RWA35030

47

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.10 RULES FOR REFUELLING AND ADDING OIL

• Spilled fuel or oil make the ground slippery and may cause ac-

cidents; clean any dirty area immediately and carefully.

• Always tighten the fuel tank and hydraulic circuit oil safety caps

securely.

• Do not use fuel to clean any part of the machine that m ay be

dirty with oil or dust.

• Always top up the fuel and oil tanks in properly ventilated place

and avoid smoking.

• When refuelling, hold the fuel gun firmly and keep it constantly

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

• Do not fill the tank completely, in order to leave room for the fu-

el to expand.

2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR

• Let the engine and the radiator cool down, before checking the

coolant level in the radiator.

RWA00970

RWA00980

• If it is necessary to r emove the cap with hot engine, wear suit-

able clothes and prot ections and loo sen the cap s lowly, in or­der to gradually release the pressure.

2.8.12 USING LAMPS

• When checking the fuel , oil, coolant o r batter y electrolyte l ev-

els, always use homologated explosion-proof lamps.
If such lighting equipment is not used, there is danger of fire or
explosion.

RWA01340

RWA01350

48

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

IMPORTANT

☞

2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR

• When repairing the electrical system , disconnet the batte ry in

order to stop the flow of current.

• Disconnect first the negative earth cable (-) and then the

positive cable (+).
At the end of the operation, reconnect first the pos itive ca­ble (+) and then the negative cable (-).

• If electrical welding operations are to be carried out on the ma-

chine, it is necessary to disconnect the battery and also the al­ternator.

REMOVAL

12

RWA01370

RWAA0040

2.8.14 PRECAUTIONS CONCERNING THE STARTER

• Start the engine only when correctly seated in the driving posi-

tion.

• Do not attempt to star t the engine by causing a short-circuit

with the terminal s of the starter. This may cause fires, serious
injuries and even death in cas e o f s udd en o r ac ci den tal move­ments of the machine.

RWA04890

RWAA0850

RWAA0850

49

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.15 PRECAUTIONS CONCERNING THE GEARSHIFT

• If electrical welding operations are to be carried out on the ma-

chine, it is necessar y to disconnect the connector (1) of the
gearshift unit positioned under the steering wheel.
To reach the c onnector (1), first remove the protection casin g
(2).

2

RWAA9260

1

RWAA0970

2.8.16 HANDLING HIGH-PRESSURE PIPES

• Do not bend high-pressure pipes or rub them with abrasive or cutting objects.

Do not use any bent or cracked pipes or ho se s that were previously rejected because of l eak s or fastening de­fects, since they may burst during use.

• Always repair or replace any loose or faulty fuel or oil pipe. Any leakage of fuel or oil may cause fires.

2.8.17 PRECAUTIONS T O BE T AKEN WHEN

DANGEROUS!

HANDLING HIGH-PRESSURE OIL

• Do not forget that the work equipment circu its are always un-

der pressure; for this reas on, when it is necessar y to add or
drain hydraulic oil or to perform maintenanc e operations or in­spections on the hydraulic circuit, it is advisable to lower the
equipment to the ground and completely release the pressures
and the residual pressure present in the tank.
Small leakages from pipes under pressure and the resulting
jets are extremely dangerous, since they can perforate the skin
and penetrate in the blood circulation or injure the eyes.
For this reason, always wear goggles and thick gloves durin g
the inspections and use a piece of cardboard or a sheet of ply­wood to check for oil leakages.
If you are hit by a jet of high-pressur e o il or ar e inj ur ed, even if
slightly, immediately consult a docto r.

CORRECT

RWA01480

50

RWA01580

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.18 PRECAUTIONS FOR MAINTE­NANCE WORK INVOLVING HIGH
TEMPERATURES AND PRESSURES

• When the machine is stopped at the end of operations, the en-

gine coolant, the oil an d all the components are hot and the
hydralic circuits are under pressure.
In these conditions, if the coolant, the hydraulic oil and the en­gine oil are to be drained in order to change them or the filters,
there are serious risks of damage and burns.
Wait for the temperature to lower within the nor mal operating
range (40÷45) before carrying out the maintenance operations
in accordance with the procedures indicated in the relevant
sections of this manual.

2.8.19 COOLING FAN AND FAN BELT

RWA00990

• Be careful to the revolving par ts and do not allow anyone to

get too close to these par t s, since cloth es or pa rts of the body
may get caught into them.

• If hands, clothes, or tools touch the fan blades or the belt, they

may be cut, torn or s eriously dama ged; for this reason, avoid
touching the revolving parts.

2.8.20 WASTE MATERIALS

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

• Always put used oil in containers. Never drain the oil directly

onto the ground.

RWA01660

• Keep to the laws and regulation s in force when disposing of

harmful su bstanc es s uch as oil, fuel, solvents, used filters and
batteries.

RWA01670

51

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.21 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES

• When being inflated, the tyres may explode and come off, thus

causing serious accidents.

• Before inflating the tyres, always check the conditions of the

rims and the outer condi tions of the tyres themselves, in order
make sure that there are no dents, cuts, torn plies or ot her de­fects.

• It is advisable to have these checks and main tenance opera-

tions carried out by a specialized technician.

• Inflate the tyres using a protection str ucture and a pneuma tic

inflating gun with extension comp lete wit h contr olling pres sure
gauge.

• Before starting thi s operation, make sure that there is no on e

in the vicinity and position yourself in front of the tread.

• Do not exceed the inflation pres s ur es pr es cr i bed for the singl e

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

RWA01680

2.8.22 PRECAUTIONS FOR THE INSTAL­LATION OF THE EXHAUST SYSTEM
TAILPIPE

• When the machine is stopped a t the end o f work, the exhaust

pipe (1) and the tailpipe (2) are ver y ho t. In these c ond iti ons, if
any maintenance operation has t o b e c arried out, the operator
runs the risk of being burned or injured.
Carry out any maintenanc e operation only w hen the tempera­ture of these parts is normal and in any cas e always use thick
gloves.

• Be part icularly careful when reasse mbling the tailpipe (2) on

the exhaust pipe (1).
The tailpipe (2) must be pos i tio ned in the cor rec t d ir ec tio n an d
respecting the angles indicated in the figure (A).
By following the procedure indicated above, you prevent the
exhaust gases from being di r ec ted towards the cab a nd there­fore towards the operator.

A

2

1

RWA33380

60˚

2

1

52

RWA33390

PRECAUTIONS TO BE TAKEN DURING MAINTENANCE

2.8.23 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADA­BLE OIL TYPE HEES

• It is not possible to mix the synthet ic biodegradable oil type HE ES with or dinar y hydraulic oils, since when the

temperature increases insoluble compounds are generated, which are depos ited on the filters and c log them
(the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil).

• The biodegradable oil can be used only in the hydraulic sy stem; it canno t be used for the endothe r mic engin e,

the transmissions, the braking system, etc.

• Before introducing the synth etic biodegradable oil in the hydraulic system, empty the s ystem completely, dis-

connecting the cyl inders an d all the p ar ts t hat may contain or dinar y oi l, and r eplace the drain filter with a new
one.
Start the engine and let i t idle without using the work equipm ent , wait unti l the oi l rea ches a temperatur e of at
least 40°C, then start moving the e quipment, so tha t all the parts of the system are filled wit h oil. Stop the en­gine and check the oil level (see “4.7.3.e CHECKING THE HYDRAULIC SYSTEM OIL LEVEL”).

53

THIS PAGE WAS INTENTIONALLY LEFT EMPTY

54

THE MACHINE AND
ITS OPERATIONS

SAFETY LOCKS

IMPORTANT

☞

3.1 SAFETY LOCKS

DANGER

• If it is necessary to carry out maintenance operations or

to stop the machine with raised loader arm, always en­gage the mechanical safety lock and the control lever
lock.

A

• 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 antirota­tion lock and the teeth protection. Use only the two-wheel
steering.

• When travelling on roads or when the backhoe is not be-

ing used, always connect the boom to the safety lock , f old
the arm and the bucket completely and lock both the
swing and the control lever. If the machine is equipped
with backhoe servo controls, always engage the control
locking safety device by pressing the relevant switch, see
“3.3.6.2 MACHINE CONTROLS (Version with servo con­trols)”, pos. 27.
Non-compliance with these rules may cause serious dam­age in case of travel downhill or accidental swing of the
equipment.

3.1.1 FR ONT LOADER LOCKS

The loader ar m is provided with two safety locks tha t have two
distinct functions regarding:

a) LOCK (1) - the posi tion of the arm when the machine is

subjected to maintena nce on the engine unit and inspec­tion of the hydraulic system e qui pme nt an d of t he auxiliary
equipment housed in the engine compar tment and in any
case to inspections and maintenance operations to be car­ried out with raised arm (A) .

b) LOCK (2) - the posi tion of the arm when the machine is

travelling on roads (B).

It is important to remember that in operating conditions the safe­ty lock (1) must be positioned against the arm (C) and secured in
that position by means of the s afety pin (3), whil e th e s afety lock
(2) must be stored in the tool case positioned inside the cab, un­der the seat support.

1

3

RWA04350

B

2

3

• The safety locks (1-2) must always adhere to the stems of

the hydraulic cylinders on whose eyes they are applied.

• The safety locks must be positioned definitively by bring-

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

• When the safety locks are in their definitive position, fas-

ten them with the safety pins (3).

RWA04360

56

SAFETY LOCKS

C

1

3

The other applications of the safety locks concern:

a) Installation of the front bucket swing lock (1).
b) Engaging of the front loader (2) control lever lock.
c) Installation of the teeth protection casing (3).

RWA04370

1

RWAA0770

2

3

RWA26220

RWA31270

57

SAFETY LOCKS

IMPORTANT

☞

3.1.2 BACKHOE LOCKS

The backhoe is held c ompletely raised by a s ingle cou pling th at
does not permit the lowering of th e boom.
The other safety device regards the swing, which is locked, ei­ther 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 - Raise the safety lock (1) by pressing the control switch (led

on) positioned on the side dashboard (see “3.3.2 pos. 20”).

3 - Rais e th e boo m completely and engage the safety lock (1)

by pressing the switch again (led off).
4 - Rotate the boom and insert the antirotation pin (2).
5 - Install the safety chains (5) f or the stabilizers.
6 - Stop the engine a nd shift th e levers (3) to sett le the safety

locks.
7 - Engage the control lever lock (4).

• If the machine is equipped with backhoe servo controls,

always engage the control locking safety device by press­ing the relevant switch, see “3.3.5.2 MACHINE CONTROLS
(Version with servo controls)”, pos. 26.

RWAA0780

1

RWAB0090

2

1

RWAB0080

3

5

58

4

RWA34830

RWA03650

3.2 GENERAL VIEWS

3.2.1 FRONT GENERAL VIEW

RWA26240

GENERAL VIEWS

4

2

2

RIGHT

FORWARD

1 - Front bucket
2 - Bucket dumping cylinder
3 - Bucket lifting arm
4 - Cab

1

5

6

7

3

LEFT

5 - Rear axle
6 - Fuel tank
7 - Lifting cylinder
8 - Front axle

8

59

GENERAL VIEWS

3.2.2 BACKHOE GENERAL VIEW

RWA26350

RIGHT

3

4

5

6

2

7

FORWARD

1 - Bucket
2 - Buc ket cylinder
3 - Arm
4 - Boom
5 - Arm cylinder
6 - Boom cylinder
7 - Hydraulic oil tank

1

13

11

12

10

8 - Stabilizers

9 - Backhoe sliding guides
10 - Backhoe locking cylinders
11 - Boom swing cylinders
12 - Sliding plate
13 - Revolving support

9

8

LEFT

60

3.2.3 CAB INSIDE GENERAL VIEW

3.2.3.1 CAB INSIDE GENERAL VIEW (Standard version)

GENERAL VIEWS

2

1

8

1 - Reversing gear-gearshift control lever
2 - Steering wheel
3 - Front dashboard
4 - Direction selector - dimmer switch
5 - Steering wheel adjustment lock
6 - Front loader control lever
7 - Accelerator pedal
8 - Brake pedals

9 - Side dashboard
10 - Hand accelerator
11 - Parking brake
12 - Arm and swing control lever

(Standard version “ISO system controls”)

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

13 - Boom and bucket control lever

(Standard version “ISO system controls”)

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

14 - Right stabilizer control lever
15 - Left stabilizer control lever

7

RWA16630

4

3

6

RWA34820

RWA16650

12

15

6

9

1

0

2

3

10

11

1

5

13

14

RWA34840

61

INSTRUMENTS AND CONTROLS

2

1

8

7

6

3

4

RWA16630

3.2.3.2 CAB INSIDE GENERAL VIEW (Version with servcontrols available on request)

RWA38250

15

14

6

9

1

0

2

3

10

11

1 - Reversing gear-gearshift control lever
2 - Steering wheel
3 - Front dashboard
4 - Direction selector - dimmer switch
5 - Steering wheel adjustment lock
6 - Front loader control lever
7 - Accelerator pedal
8 - Brake pedals

9 - Side dashboard
10 - Hand accelerator
11 - Parking brake
12 - Arm and swing control lever

(Standard version “ISO system controls”)

- Boom and swing control lever
(On request only with “Komatsu system contr ols” Patt er n
Change)

13 - Boom and bucket control lever

(Standard version “ISO system controls”)

- Arm and bucket control lever
(On request only with “Komatsu system contr ols” Patt er n
Change)

14 - Right stabilizer control switch
15 - Left stabilizer control switch

RWA16650

1

5

12

13

RWA37750

62

3.3 INSTRUMENTS AND CONTROLS

3.3.1 FRONT INSTRUMENTS

RWA27790

17

4

10

3

2

1

C

H

E

C

K

+

-

15

S

E

R

V

IC

13

5

6

7

8

E

9

16

14

11

12

INSTRUMENTS AND CONTROLS

1 - Transmission oil temperature warning

light

2 - Engine coolant temperature warning

light

3 - Four-wheel drive engageme nt warning

light
4 - Low fuel warning light
5 - Direction indicator warning light
6 - High beam warning light
7 - Parking brake and brake oil level warn-

ing light
8 - Warning light available for optional

equipment
9 - Direction selector, dimmer switch, horn,

blinking

10 - Four-wheel drive push button
11 - Front windshield wiper / washer switch
12 - Front working light switch
13 - Emergency switch (HAZARD)
14 - Switch available for optional equipment

15 - Electric safety valve switch (if installed)
16 - Steering push-button unit

17 - Electronic display

1 - TRANSMISSION OIL TEMPERATURE WARN-

ING LIGHT

This warning light comes on and the acoustic alarm sounds
when the transmission oil temperature exceeds the maximum
value allowed; when it comes on, immediately stop the machine,
shift the gears into neutral and let i t cool down with the engin e
running at about 1200 rpm until the warning light goes out.
When the warning light (1) comes on, the operator is warned
about the failure also through the electronic display pos. 17.
If this inconvenience occurs repeatedly, have the machine
checked and if necessary repaired by an authorized repair shop.

2 - ENGINE COOLANT TEMPERATURE WARN-

ING LIGHT

This warning light comes on and the acoustic alarm sounds
when the engine coolant temperature exceeds the maximum
value allowed; when it comes on , let the engine i dle (1200 rpm)
until the warning light goes out. When the warning light (2)
comes on, the operator is war ned about th e failure also throug h
the electronic display pos. 17.
If this inconvenience occurs again, make sure that the radiator is clea

3 - FOUR-WHEEL DRIVE ENGAGEMENT WARN-

ING LIGHT

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

1

RWA02580

2

2

1

3

4

3

4

4 - LOW FUEL WARNING LIGHT

This warning light comes on when about 17 l. of fuel a re left in t he
tank and therefore it is necessary to refuel as soon as possible.

63

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

5 - DIRECTION INDICATOR WARNING LIGHT

This warning light comes on in termitten tly when the l ever (9) or
the emergency switch - pos. 13 - are operated.

OPT

6 - HIGH BEAM WARNING LIGHT

It comes on when the high beam is operated through the dimmer
switch - pos. 9.

7 - P ARKING BRAKE AND BRAKE FLUID LEVEL

WARNING LIGHT

This warning light indicates t hat the park ing brake has been ap­plied or that the brake fluid l evel is low; if it comes on for the lat­ter cause, stop the machine and top up the brake fluid.
If this occurs repeate dly, check the braking syste m in order to
eliminate any leakage.

8 - WARNING LIGHT AVAILABLE FOR OPTION-

AL EQUIPMENT

9 - DIRECTION SELECTOR, DIMMER SWITCH,

HORN, BLINKING

This is a combine d switch positioned under the steering wheel ,
on the right s ide, and c ontrols t he dire ction i ndicators, the lights
and the horn. By rotating it one click anticl ockwise it is possible
to switch on the park ing lig hts and the instr ument lighting , while
with two clicks the low beam comes on.
It is possible to switch over from low beam to high beam by
pushing the lever downwards (position D), wh ile the lights blink
when the lever is pushed upwards (position E).
Push the lever forward (position A) to si gnal left, pull the lever
backward (position B) to signal right.
Press (C) to sound the horn.

5

RWA38610

6

6

5

7

8

RWA26470

7

8

A

E

C

9

B

D

10 - FOUR-WHEEL DRIVE PUSH BUTTON

This button is positio ned on the transmission co ntrol and when
pressed it selects the 4WD (four-wheel drive), which is si gnal le d
by the coming on of the relevant green led.
In this position also the warning light pos. 3 comes on.
When the button is pressed again (led off), it disconnects the
four-wheel drive while the ma chine automaticall y returns to the
normal drive.
For further details, see “3.3.5 pos. 1 REVERSING GEAR­GEARSHIFT LEVER”.

• When travelling at high speed and on roads, disengage

the four-wheel drive.

64

RWA16680

10

10

+

-

11 - FRONT WINDSHIELD WIPER / WASHER

IMPORTANT

☞

SWITCH

With the first click it operates the windshield wiper, while with the
second click (with automatic return to the first) it operates the
windshield washer.

12 - FRONT W ORKING LIGHT SWITCH

This switch enables the front working light circuit.

• When travelling on roads, turn off the working lights.

15

INSTRUMENTS AND CONTROLS

13

12

11

13 - EMERGENCY SWITCH

This switch simultaneously ope rates all the direction lights an d
must be during road travel whenever the machine is temporari ly
stopped on the roadway or however in anomalous positions.

14 - SWITCH A VAILABLE FOR OPTIONAL EQUIP-

MENT

15 - ELECTRIC SAFETY VALVE SWITCH

(if installed)

This is a two-position switch.
When pressed, it remains in the low position, the relevant red led
comes on and the safety valves installed on the cyli nders of th e
front loader are deactivated.
When released, it returns to its original position, the safety
valves are activated and at the same time the red led goes out.

• 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)”.

RWA31500

15

13

12

11

14

16 - STEERING CONTROL PUSH-BUTTON UNIT

This is a control with micr oswitches in pairs, giving the oppo rtu­nity to select from three different steering modes:

A) two-wheel steering
B) all-wheel steering
C) crab steering.

For its use, see “3.3.5 pos. 2 STEERING SELECTOR UNIT”.

SERVICE

B

A

C

RWA26480

65

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

17 - ELECTRONIC DISPLAY

The electronic display (17) shows the alignme nt of the front and
rear axles, besides managing and displaying several functions,
at the same time controlling them completely and effectively:

• speedometer, with indication in km/h and Mp/h;

• situation of the routine maintenance operations to be per-

formed every 500, 1000 and 2000 hours;

• maintenance and emergency indicators;

• other messages.

After introducing the key and switching on the board, that is,
making one click only with the key (in this phase the e ngine is
off), it is possible to dis play all the following information in s e­quence, by pressing the CHECK button (1) only with the rear ax­le aligned.

1 - Partial service hours

Storage and display of the ser vice hours between two succes­sive maintenance operations. To set the number of service hours
to zero, keep the SERVICE button (2) pressed for approximately
5 seconds.
The display (16) will show some symbols with the respective
service hours, in the following order:

• Engine oil.

17

1

C

H

E

C

K

2

S

E

R

V

IC

E

RWA27800

• Engine oil filter.

• Fuel filter.

• Air cleaner.

• Transmission filter.

• Brake oil.

• Coolant.

• Hydraulic oil.

• Set the service hours to zero only after performing the re-

quired maintenance operation.

2 - Types of oil

Indication of the type of oil us ed in the machine, specifical ly for
the following systems:

• Engine oil and transmission oil (see Fig. A)

• Brake oil and hydraulic oil (see Fig. B)

A

SAE 10W-30

ANDROS FLUID II D

B

ANDROS FLUID II D

RWA01960

RWA26500

!

SAE 10W-30

RWA26510

66

3 - Maintenance plan

The display shows the maintenance plan in the following order:

• Maintenance operations to be perfor me d every 500 hour s (en-

gine oil, fuel filter, air cleaner and engine oil filter).

• Maintenance operations to be performed every 1000 hours

(transmission filter).

INSTRUMENTS AND CONTROLS

500H

RWA26520

• Maintenance operations to be performed every 2000 hours

(engine coolant, hydraulic oil and brake oil).

1000H

RWA26530

!

2000H

RWA26540

67

INSTRUMENTS AND CONTROLS

When a maintenance alar m is sent out, the display (17) keeps
showing the speedometer together with the ”CHECK” signal
(see figure A or B).

A

000KM/h

By pressing the CHECK button (1), it is possible to display what
maintenance operation must be performed.
If more than one mainte nance operation must be performed at
the same time, they ca n be displayed in sequence by pressing
the SERVICE button (2):

• Every 500 hours:

- Engine oil (Fig. C)

- Engine oil filter (Fig. D)

- Fuel filter (Fig. E)

- Air cleaner (Fig. F)

CHECK

B

000MP/h

CHECK

17

1

C

H

E

C

K

S

E

R

V

IC

E

RWA26550

RWA26560

2

RWA27800

68

C

500H MOTOR
OIL

D

500H MOTOR
FILTER

RWA26580

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

• Every 1000 hours:

- Transmission filter (Fig. G)

• Every 2000 hours:

- Brake oil (Fig. H)

- Coolant (Fig. I)

- Hydraulic oil (Fig. L).

To return to the speedometer, press the CHECK button (1)
again. Once the require d maintenance operation has bee n car­ried out, it is possible to res et the partial ser vice hours for that
specific maintenance operation, by showing the operation on the
display (17) and keeping the SERVICE button (2) pressed for
approximately 5 seconds.
The partial number of hours is thus cancelled and the count
starts agai n, for each mainte nan ce func tio n, fr om th e mom ent in
which the reset of the alarm is carried out.

• Set the service hours to zero only after performing the re-

quired maintenance operation.

• The maintenance alarms must be accompanied by the

flashing of the danger symbol ( ).

E

500H FUEL

FILTER

F

500H AIR
FILTER

G

1000H FILTER

GEARING

H

2000H BRAKE
OIL

RWA26640

!

RWA26700

I

2000H COOLANT

FLUID

L

2000H HYDRAULIC
OIL

RWA26760

69

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

IMPORTANT

☞

IMPORTANT

☞

4 - Language selection

It is possible to display the list of all the languages available, in
the following order:

• Italian

• English

• German

• French

• Spanish

• Portuguese

• To select a language, move to the desired page by press-

ing the SERVICE button (2).

5 - Speed indication

Display of the machine speed during travel.
According to the traffic r ule in force, it is possible to cho ose from
two units of measurement:

• Km/h

• Mp/h

CHECK

CHECK

SELECTION

LANGUAGE

ENGLISH

INDICATION

OF SPEED IN

KM

/h M

P/H

2

SERVICE

RWA26820

2

SERVICE

• To select one of the two units of measuremen t, move to

the desired page by pressing the SERVICE button (2).

6 - Tyre pressure

Display of the correct t yre pressure for the front an d rear tyres.
The pressure measured when checking the tyres must corre­spond to that indicated on the display.

For further informatio n on the tyre pressure check, see “4.7.6.e
CHECKING THE TYRE PRESSURE” and “5.1.3 TECHNICAL
CHARACTERISTICS”.

• On this screen page it is possible to select the tyre cir-

cumference by keeping the SERVICE button (2) pressed
for approximately 10 seconds. The selection of the cir­cumference depends on the type of tyre installed on the
machine.
Therefore, for a correct selection of the circumference val­ue, keep to the following indications:

- with tyre 16.9-24 = wheel 3.819

- with tyre 16.9-28 = wheel 4.144
To carry out a selection, move to the desired page by
pressing the SERVICE button (2).

CHECK

CHECK

TYRE

PRESSURE 4RS

FRO

NT. 2.2

REAR. 2.6

16.9 - 24

16.9 - 28

RWA26880

2

SERVICE

RWA26940

2

SERVICE

70

RWA27810

7 - Operation alarms

Besides the functions described before, the display (17) has also
the function to warn the operator in case of problems on s ome
machine components.
These alarms take priority over any other message displayed
(maintenance alar ms) and are ac companie d by an acoustic sig­nal.

When the machine is started, while the steering system per­forms the tests on the s olenoid valves, the writing ”KOMATSU”
appears for a few seconds on the display (17).

INSTRUMENTS AND CONTROLS

17

CHECK

SERVICE

17

KOMATSU

CHECK

SERVICE

RWA27820

Successively, if no malfuncti on has been found, the spe edome­ter appears on the display (17) (see Figure A or B).

RWA27840

A

17

000KM/h

CHECK

SERVICE

RWA27850

B

17

000MP/h

CHECK

SERVICE

RWA27860

71

INSTRUMENTS AND CONTROLS

If a malfunction shoul d be found in the steer ing soleno id valves,
the relevant message will appear on the display (17) and an
acoustic signal will be sen t forth, according to the solenoid valve
presenting the failure.

• Crab steering solenoid valve failure.

• All-wheel steer in g sol eno id valve failure.

CHECK

CHECK

MISTAKE

ELECTROVALVE

CRAB

MISTAKE

ELECTROVALVE

ROUND

SERVICE

RWA27260

SERVICE

• Four-wheel steering solenoid valve failure.

• Two-wheel steering solenoid valve failure.

CHECK

CHECK

MISTAKE

ELECTROVALVE

4RS

MISTAKE

ELECTROVALVE

2RS

RWA27380

SERVICE

RWA27440

SERVICE

72

RWA27500

• Rear potentiometer failure

Other operation alar ms that can be shown on the display (17)
are the following:

• Alternator failure.

INSTRUMENTS AND CONTROLS

SHORT/OPEN

REAR

CHECK

POTENTIOMETER

SERVICE

17

BATTERY

RWA27570

• Insufficient engine oil pressure.

CHECK

CHECK

17

LOW
PRESSURE
OIL

SERVICE

RWA27870

SERVICE

RWA27890

• Maximum coolant temperature.

CHECK

17

OVERTEMP.
COOLANT
FLUID

SERVICE

RWA27900

73

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

• Air cleaner clogging.

CHECK

17

AIR
FILTER
STOPPING

SERVICE

RWA27910

• Converter oil maximum temperature.

• When an operation alarm is sent forth, stop the machine,

engage all the safety locks and carry out the necessary re­pair.

• The acoustic alarm sends out two different sounds: an in-

termittent sound for the steering alarms and a continuous
sound for all the other types of alarm.
For further information on the acoustic alarm, see “3.3.2
SIDE INSTRUMENTS pos.10”.

CHECK

17

OVERTEMP.
GEARING
OIL

SERVICE

RWA27920

74

3.3.2 SIDE INSTRUMENTS

3.3.2.1 SIDE INSTRUMENTS (Standard version)

1

7

6

5

4

16

14

15

3

2

8

9

10

21

11

12

13

17

1

0

2

3

20

19

18

RWA34850

INSTRUMENTS AND CONTROLS

1 - Fuel level indicator
2 - Revolution counter - Hour meter
3 - Engine coolant temperature indicator
4 - Air cleaner clogging warning light
5 - Engine oil pressure warning light
6 - Glow plug preheating warning light
7 - Generator warning light
8 - Engine coolant temperature warning

light

9 - Available for optional equipment warn-

ing lights
10 - Acoustic alarm
11 - Rear working light switch
12 - Rear windshield wiper / washer switch
13 - Revolving light switch
14 - Rear horn
15 - Air conditioner switch (if provided)
16 - Load stabilizer system switch (if p rovid-

ed)
17 - Ignition switch
18 - Fan switch
19 - Backhoe speed control button
20 - Backhoe boom lock switch
21 - Backhoe sliding lock switch

75

INSTRUMENTS AND CONTROLS

3.3.2.2 SIDE INSTRUMENTS (Version with servo controls available on request)

1 - Fuel level indicator
2 - Revolution counter - Hour meter

21

20

19

24

23

22

10

9

12

8

11

1

0

2

3

18

RWA37760

1

7

6

5

4

2

3

13

15

14

17

16

3 - Engine coolant temperature indicator
4 - Air cleaner clogging warning light
5 - Engine oil pressure warning light
6 - Glow plug preheating warning light
7 - Generator warning light
8 - Engine coolant temperature warning

light

9 - Available for optional equipment warn-

ing lights
10 - Acoustic alarm
11 - Rear working light switch
12 - Rear windshield wiper / washer switch
13 - Revolving light switch
14 - Rear horn
15 - Air conditioner switch (if provided)
16 - Load stabilizer system switch (if p rovid-

ed)
17 - Ignition switch
18 - Fan switch
19 - Backhoe speed control button
20 - Backhoe boom lock switch
21 - Backhoe sliding lock switch
22 - Backhoe control locking switch (only in

the version with servo controls)
23 - Left stabilizer control switch (only in the

version with servo controls)
24 - Right stabilizer control switch (only in

the version with servo controls)

76

INSTRUMENTS AND CONTROLS

1 - FUEL LEVEL INDICATOR

It indicates the fuel level in the tank; this indicat ion is given only
when the ignition key is in position «I» (see pos. 17).

2 - REVOLUTION COUNTER - HO UR METER

This is a combine d inst rument th at indica tes the eng ine r unnin g
speed with a pointer, while the number of operating hours ap­pears on the lower displays.
The reading is to be co nsidered valid for the calculation of the
maintenance intervals.

RWA02620

15

10

20

RPM x 100

electronic

25

30

5

1

RWA02630

2

15

10

20

RPM x 100

electronic

25

30

5

3 - ENGINE COOLANT TEMPERATURE INDICA-

TOR

It indicates the engine coolant temperature, which normally must
be included between 80 and 85°C.

RWA02640

5

10

RPM x 100

15

electronic

20

25

30

3

77

INSTRUMENTS AND CONTROLS

4 - AIR CLEANER CLOGGING WARNING LIGHT

This warning light comes on and the acoustic alarm sounds
when the engine air filter needs cleaning. When the warning light
(4) comes on, the operator is warned about the inconvenience
even through the electronic display positioned on the front das h­board.
See “3.3.1 FRONT INSTRUMENTS” pos. 17).

5 - ENGINE OIL PRESSURE WARNING LIGHT

This warning light comes on and the acoustic alarm sounds
when the engine i s n ot running and the starting circuit is op erat­ed and goes out as soon as the engine lubrication circuit is pres­surized. If this war ning light does not go ou t or comes on when
the engine is running, s top the machine immediat ely and try to
find the cause of the failure. When the warning li ght (5) comes
on, the operator is warned about the inconvenience even
through the electronic display positioned on the front dashboard.
See “3.3.1 FRONT INSTRUMENTS” pos. 17.).

4

RWA02650

5

6

5

4

6

7

7

15

10

20

RPM x 100
electronic

25

30

5

6 - GLOW PLUG PREHEATING WARNING LIGHT

It comes on when the ignit ion key is tur ned to position «» for
the cold start of the engine (see “3.6.2.2 STARTING WITH
COLD ENGINE OR IN COLD CLIMATES”).

7 - GENERATOR WARNING LIGHT

This warning light comes on and the acoustic alarm sounds
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 r unning at the nor mal operating speed, t his
means that the alter nator is not working and th e battery is not
charged correctly.
When the warning light (7) comes on, the operator is warned
about the inconvenience even through the electr onic display po­sitioned on the front dashboard. See “3.3.1 FRONT INSTRU­MENTS” pos. 17.

78

8 - ENGINE COOLANT TEMPERATURE WARN-

IMPORTANT

☞

ING LIGHT

This warning light comes on and the acoustic alarm sounds
when the engine coolant temperature exceeds the maximum
value allowed; in this case, lower the eng ine s pee d to i dli ng (ap­proximately 1200 r pm) an d wait u ntil it stop s. When the war nin g
light (8) comes o n, the operator is war ned about the in conven­ience even through the electronic display positioned on the front
dashboard.
See “3.3.1 FRONT INSTRUMENTS” pos. 17.

9 - WARNING LIGHTS AVAILABLE FOR OP-

TIONAL EQUIPMENT

8

15

10

RPM x 100

electronic

RWA02660

INSTRUMENTS AND CONTROLS

OPT OPT OPT

9

20

25

30

8

9

9

9

9

9

10 - ACOUSTIC ALARM

This alarm starts when the ci rcuits are energized by means of
the ignition key (by turning it to position «I») and is automatically
disconnected when the engine starts.
The sounding of the continuou s alar m du r ing the us e of the ma­chine signals the following:

• Insufficient engine oil pressure.

• Overheating of the engine cooling circuit.

• Overheating of the transmission oil.

• Faulty alternator or worn belt.

• Air cleaner clogged.

• Incorrect position of the seat for travelling.

The sounding of the intermittent alarm duri ng the use of the ma­chine signals the following:

• Real wheels misalig ned either with ma chine moving and wi th

machine at rest.

• Steering solenoid valve malfunction.

• Incorrect gear se lection with respect to the s elected steering

mode.

10

RWA02720

• Before using the machine, make sure that the acoustic

alarm (10) functions perfectly. If the alarm doesn’t work,
have the machine checked by your Komatsu Utility Dealer.

79

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

11 - REAR WORKING LIGHT SWITCH

This switch enables the rear working light circuit.

• When travelling on roads, turn off the working lights.

12 - REAR WINDSHIELD WIPER / WASHER

SWITCH

With the first click it operates the windshield wiper, while with the
second click (with automatic return to the first) it operates the
windshield washer.

13 - REVOLVING LIGHT SWITCH

This switch must be operated when it is necessary to travel on
roads and after connecting the light to the outlet (see “3.3.4 pos.
2”).

5

RWA02670

13

10

RPM x 100

electronic

12

15

20

25

30

12

11

13

11

14 - 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.

15 - AIR CONDITIONER SWITCH (if provided)

When this switch is pressed, the r elevant green led comes on
and the air conditioner is started.
For further informa tion on the operation of the air condi tioning
system, see “3.5.5 AIR CONDITIONER”.

16 - LOAD STABILIZER SYSTEM SWITCH (LSS)

(if provided)

When this switch is pressed , the green led comes on and the
load stabilizer system is operated.
To recharge the battery and to keep the pressure constant,
press the switch. For further information on the LSS system, see
"6.11 LOAD STABILIZER SYSTEM (LSS)".

RWA33740

16

16

15

15

14

5

14

10

RPM x 100

R

15

electronic

20

25

30

80

17 - IGNITION SWITCH

The ignition switch is a rotary key switch with four positions
marked with the following symbols: «» - (OFF) - I - «»
(START).
For further details on the us e of this switch see “3.6.2 START­ING THE ENGINE”).

17

INSTRUMENTS AND CONTROLS

1

0

2

RWA31210

18 - FAN SWITCH

It is a three-speed switch and operates the fan motor. Tur n the
switch clockwise to increase the fan speed.
If operated after the opening of the cock installed on the heater,
it ensures the circulation of warm air and serves as heating
switch (see “3.5.4 VENTILATION AND HEATING”).
The temperature of the air conveyed by the heater is regulated
through the knob (T).
Tur n the knob cl ockwise to increase the temperature and coun­terclockwise to reduce it.
If the machine is provided with air conditioning system, the three
knobs (T), (18) and (R ) can be used to adjust the air flow and
therefore to choose the temperature inside the cab.
For further information, see “3.5.5 AIR CONDITIONER”.

RWA34870

1

0

2

3

R

18

T

81

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

IMPORTANT

☞

IMPORTANT

☞

19 - BACKHOE SPEED CONTROL BUTTON

This button permits the selection of the oil delivery of the hydrau­lic pump. Whenever restarted, the machine automatically selects
the POWER mode (LED on), even if when it stop ped the sele ct­ed mode was ECONOMY. Th is pos iti on ma kes it possible to use
the maximum oil delivery and is indispe nsable for a correct use
of the backhoe. When the button is pressed (LED off), the
ECONOMY operation mode is selected. To return to the POW­ER mode (LED on), press the button agai n. The machine pass­es automatically from th e POWER to the ECONOMY operatio n
mode when the forward or the reverse gear are engaged (invert­er control lever forward or backward). To return to the POWER
operation mode, shift the lever back to the neutral position.

POWER

19

20

21

RWA31230

21

• If the machine is equipped with backhoe servo controls,

the switch (19) is positioned on the upper part of the side
dashboard, as shown in Fig. A.

20 - BACKHOE BOOM LOCK SWITCH

This switch is used to couple the safety lock with the boom when
the backhoe is not used or when travelling. The safety lock is en­gaged when the switch is off (led off), whi le its disengagement
takes place when the switch is on (led on). (See “3.3.5 pos. 9”).

• If the machine is equipped with backhoe servo controls,

the switch (20) is positioned on the upper part of the side
dashboard, as shown in Fig. A.
The specific function of the switch (20) can be disabled
through the control locking switch (22).
For further information, see “22 - CONTROL LOCKING
SWITCH (Version with servo controls)”.

21 - BACKHOE SLIDING LOCK SWITCH

This switch has the function to release the backhoe unit from the
sliding guides, i n 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 locked on the guides a nd the switch is
not operated (led off). When pre ssed, the switch comes on and
releases the unit from the guides, thus allowing th e backhoe to
slide; once the desired position has been reached, press the
switch again to lock the backhoe unit (led off).

POWER

19

A

22

20

19

21

19

20

20

22

21

RWA37770

• If the machine is equipped with backhoe servo controls,

the switch (21) is positioned on the upper part of the side
dashboard, as shown in Fig. A.
The specific function of the switch (21) can be disabled
through the control locking switch (22).
For further information, see “22 - CONTROL LOCKING
SWITCH (Version with servo controls)”.

82

22 - BACKHOE CONTROL LOCKING SWITCH

(Version with servo controls only)

This switch has the speci fic function to disable all the backhoe
controls and this function must always be activated when the
backhoe is not used or when travelling on roads. To activate the
control locking function, press the switch (22). The actual locking
of the controls is indicated by the co ming on of the correspo nd­ing warning light. To deactivate this function, press the switch
(22) again until the cor responding warning light goes out. The
backhoe control locking function is automatically activated at
each start of th e machine and is signalled by the coming on of
the corresponding war ning light. For further informat ion on the
operation of this switch, see “3.3.5.2 MACHINE CONTROLS
(Version with servo controls)” pos. 26.

INSTRUMENTS AND CONTROLS

22

22

23

23

24

24

RWA37780

23 - LEFT STABILIZER CONTROL SWITCH

(Version with servo controls only)

This switch controls the lifting and lowering of the left stabilizer.
Push the switch (23) towards the outside of the cab to lower the
left stabilizer. To lift the stabilizer, pull the switch (23) towards the
inside of the cab. The function of the switch (23) can be disabled
by means of the backhoe cont rol l ocking switch (2 2). For further
information on the operation of the stabilizers, see “3.3.5.2 MA­CHINE CONTROLS (Version with servo controls)” pos. 17.

24 - RIGHT STABILIZER CONTROL SWITCH

(Version with servo controls only)

This switch controls the lifting and lowering of the right stabilizer.
Push the switch (24) towards the outside of the cab to lower the
right stabilizer. To lift th e stabilizer, pull the switch (24) towards
the inside of the cab. The function of the switch (24) can be disa­bled by means of the backhoe control l ocking switch (22). For
further information on the operation of the stabilizers, see
“3.3.5.2 MACHINE CONTROLS (Version with servo controls)”
pos. 18.

83

INSTRUMENTS AND CONTROLS

3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER

1 - Declutch push button

1

4

2

1 - DECLUTCH PUSH BUTTON

This push button is used to transform all the engine power into
hydraulic po wer for the lifting of materials.
(See “3.3.5 pos. 11 DEC L UTCH CONTROL”).

3

A

A

5

6

RWA31280

2 - Available push button
3 - 4in1 bucket opening push button
4 - 4in1 bucket folding push button
5 - Front loader speed control push button
6 - KICK-DOWN push button

OPT

2 - A VAILABLE PUSH BUTTON
3 - 4IN1 BUCKET OPENING PUSH BUTTON

Press the push button to open the bucket; when the push button
is released, the bucket stops (see “3.3.5 pos. 12 4 IN1 BUCKET
OPENING CONTROL”).

4 - 4IN1 BUCKET FOLDING PUSH BUTTON

Press the push button to fold the bucket; when the push button is
released, the bucket stops (see “3.3.5 pos. 13 4IN1 BUCKET
FOLDING CONTROL”).

5 - FRONT LOADER SPEED CONTROL PUSH

BUTTON

The front loader movement speed can be increased by means of
this push button.

1

1

2

3

3

4

4

2

RWA27550

L

56

6 - KICK-DOWN PUSH BUTTON

This is a pulse push button connected with the electronically­controlled gearshift.
It selects the 1
them engaged (see “3.3.5 pos. 6 KICK-DOWN PUSH BUT­TON”).

84

st

gear from the 2nd gear or vice versa and keeps

A

A

5

6

RWA31300

3.3.4 ELECTRICAL ACCESSORIES

1 - OVERHEAD LAMP

The overhead lamp is used to check the instr um ents an d the in­side of the cab when visibility is scarce.

2 - ELECTRIC OUTLET

The electric outlet is a 12V outlet in compliance with the ISO
4165-1979 standa rd. It is used for the connection o f the revolv­ing light and of the inspectio n lamp when maintenance opera­tions are to be carried out and visibility is scarce and for the
connection of the emergency light.
The outlet is powered with the revolving light switch (see “3.3.2
pos. 13”).

INSTRUMENTS AND CONTROLS

1

RWAA0230

2

3 - CIGARETTE LIGHTER OUTLET

The outlet (3) is positioned on the lower par t of the side dash­board and is powered by a 12V supply. It is used to for the inser­tion of the cigarette li ghter and is perfectly compatible with the
cigarette lighters available on the ma rket. The same outlet can
also be used to recharge mobile phones; before using it, remove
the safety plug (A).

4 - BATTERY DISCONNECTION SWITCH

(if installed)

The battery disconnection switch (4) is positioned on the left side
of the machine, inside the engine compartment and to reach it it
is necessary to open the engine hood (see "3.5.1 ENGINE
HOOD"). It is possible to inter rupt the passage of current fro m
the battery to the e lectric syste m of the machine by rotating th e
switch anticlockwise and removing it. Al ways interrupt the pas­sage of current be fore carr ying out any operati on on the ba tter y
or the electric system and be fore carr ying ou t any welding ope r­ation on the machine. To restore the electr ic contact, put back
the switch and rotate it clockwise.

RWAA0240

A

3

RWA38190

4

RWA37790

85

INSTRUMENTS AND CONTROLS

1

RWA38270

3

4

5

C

H

E
C

K

S
E
R

V

IC

E

2

19

3.3.5 MACHINE CONTROLS

3.3.5.1 MACHINE CONTROLS (Standard version)

RWA34890

5

10

9

1

0

2

3

8

7

1 - Reversing gear-gearshift lever
2 - Steering selector uni t

11

3 - Brake pedals
4 - Accelerator

13

5 - Front loader control lever
6 - KICK-DO WN push button
7 - Parking brake
8 - Hand accelerator

9 - Backhoe boom lock control switch
10 - Backhoe sliding lock control switch
11 - Declutch push button
12 - 4in1 bucket opening control push button
13 - 4in1 bucket folding control push button
14 - Front loader speed control push button
15 - Left backhoe control lever

15

16 - Right backhoe control lever
17 - Left stabilizer control lever
18 - Right stabilizer control lever
19 - Steering wheel adjustment locking lever

17

12

14

6

RWA27230

16

86

18

RWA34900

INSTRUMENTS AND CONTROLS

3.3.5.2 MACHINE CONTROLS (Version with servo controls available upon request)

C

H
E

C
K

S
E

R
V

IC

1

E

19

3

1 - Reversing gear-gearshift lever
2 - Steering selector uni t
3 - Brake pedals
4 - Accelerator
5 - Front loader control lever
6 - KICK-DO WN push button
7 - Parking brake
8 - Hand accelerator

9 - Backhoe boom lock control switch
10 - Backhoe sliding lock control switch
11 - Declutch push button
12 - 4in1 bucket opening control push button
13 - 4in1 bucket folding control push button
14 - Front loader speed control push button
15 - Left backhoe control lever
16 - Right backhoe control lever
17 - Left stabilizer control switch
18 - Right stabilizer control switch
19 - Steering wheel adjustment locking lever

4

RWA38270

2

5

RWA38280

18

17

9

10

26

5

1

0

2

3

8

7

11

12

13

14

6

RWA27230

15

16

RWA38320

87

INSTRUMENTS AND CONTROLS

27

28

29

15

32

20

22

24

20 - Left joystick locking lever

(only with servo control system)

21 - Right joystick locking lever

(only with servo control system)

22 - Left support adjusting knob

(only with servo control system)

23 - Right support adjusting knob

(only with servo control system)

24 - Left joystick stroke adjusting knob

(only with servo control system)

25 - Right joystick stroke adjusting knob

(only with servo control system)

26 - Backhoe control locking switch

(only with servo control system)

27 - Offset boom left swing control push button

(if installed and only with servo control system)

28 - Offset arm right swing control push button

(if installed and only with servo control system)

29 - Horn push button

(only with servo control system)

30 - Telescopic arm extension control push button

(if installed and only with servo control system)

31 - Telescopic arm retraction control push button

(if installed and only with servo control system)

32 - Hammer control push button

(if installed and only with servo control system)

33 - Pattern change control lever

(if installed and only with servo control system)

33

25

16

23

30

31

21

RWA38550

88

INSTRUMENTS AND CONTROLS

DANGER

IMPORTANT

☞

1 - REVERSING GEAR-GEARSHIFT LEVER

• Since no mechanical connection is provided between the gearshift 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.

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

ning, moves the reversing gear lever (1) t o position FWD or REV with the seat rotated in any position
different from the correct driving position.
This is a danger signa l, since it is absolutely forbidden to carry o ut any movement with the machine
while working with the ba ckhoe equipmen t or in any case w ith th e seat rotat ed by 180° with respect to
the regular driving position. Remember that the operator must carry out any movement of the machine
while seated in the correct driving position, with locked seat and fastened safety belt.

• Disconnect the connector of the reversing gear-gearshift lever unit before carrying out electric welding

operations on the machine.
Non-compliance with this rule may even result in deadly acciden ts, since the gear storage , gea r selec­tion and travel direction selection microcircuits may be irreversibly damaged.

• The engine can be started only with the gearshift lever in

neutral position (N).

• If the operator deems it n ecessary, the machine may also

be equipped with an acoustic alarm for movements in re­verse.
This device can be installed on an apposite area on the
rear part of the frame (see 2.4.3 CHECKS FOR TRAVEL­LING IN REVERSE) and before carrying out any move­ment in reverse it is recommended to make sure that this
device is functioning 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 positio n
R.
If the alarm doesn’t work, have the machine checked by
your Komatsu Utility Dealer.

This is a combined control that serves either to shift gears and to
reverse.
The gears are engaged by mea ns of the push buttons UP (2)
and DOWN (3).
The travelling direction (forward or reverse) is selected by means
of the lever (1).
The normal co ntrol of the gearshift is ensured by the semiauto­matic logic system (SA) , with possibility to select the au tomatic
logic system (AU).
The gearshift contro l is also provided with a safety code to pre­vent theft.

REV

RWA12430

2

FWD

N

1

3

+

-

89

INSTRUMENTS AND CONTROLS

MAIN FUNCTIONS OF THE GEARSHIFT CONTROL

2

FWD

1

4

5

N

REV

3

6

7

9

11

12

RWA12420

8

10

13

14

15

+

-

1 - Reversing gear lever for the forward (FWD), reverse (REV) and NEUTRAL (N) selection.
2 - (UP) push button for the upshifting.
3 - (DOWN) push button for the downshifting.
4 - Red led (N); when this led lights up, it indicates that the device preventing the accidental engagement of the

FWD or REV is connected or that the reversing gear lever is not in NEUTRAL position during the start.
5 - Green led (FWD); when this led lights up, it indicates that the forward gear has been selected.
6 - Green led (REV); when this led lights up, it indicates that the reverse gear has been selected.

st

7 - (4WD) push button for the engagement and disengagement of the four-wheel drive only in 1
8 - Gree n l ed (4 WD ); when this led is continuosly on , it indicates that the 4WD push button is pres se d an d the

four-wheel drive is engaged, when it is off, it indicates that the 4WD push button is relea sed and the four-

wheel drive is diseng aged and when it flashes, it indi cates that the 4WD push button is pressed and the

four-wheel drive has been temporarily disengaged in 3
9 - Safety code push button for the connection or disconnection of the anti-theft function.

The connection is achieved by pressing the push button for more than 3 seconds with the engine running.

10 - Safety code green led; when this led lights up, it indicates that the anti-theft function is in operation.

When the engine is started again, it is necessary to enter the secret code to be able to move the machine.

11 - Automatic log ic c onn ect ion pu sh button (AUT); the connection of the automatic l ogic (AUT) is possible on ly

with the engine running and the device preventing the accidental engagement in operation (red led N on).

The connection (AUT) is indicated by the coming on of two red points on the display (15).

12 - (DIM) push button; this button confirms and acquires the anti-theft code, regulates the luminous intensity of

the display and of the leds.

13 - Orange configuration led; it flashes when state changes are required in non-optimal field.
14 - Red al arm led; when this led is continuosl y on , it in dic ate s s erious faults associated to a figure code on the

display; when it flashes, it indicates minor faults associated to a figure code on the display.

15 - Red luminous display; it indicates the automatic lo gic state, the engaged gear, the number relevant to the

safety code, the state (88) after the energizing or the ent r y of a wrong anti-the ft code, the diagnost ic refer-

ences in case of anomaly in the transmission or in the electronic control.

rd

or 4th gear.

or 2nd gear.

90

STARTING THE ENGINE

t

IMPORTANT

☞

IMPORTANT

☞

IMPORTANT

☞

• Shift the lever to the neutral position (N), turn the ignition key to

position «I» and make sure that the display indicates (88). Star
the engine. After a quick self-test phase, the 2nd gear with semi­automatic logic (SA) will be shown on the display (15).

• If the engine is not started within 20 seconds (program-

mable) after turning the ignition key to position «I», the
electronic system inhibits the control and displays the fig­ure code dP on the display (15); turn the key to position
«» and repeat the starting procedure.

• If the lever is not in the neutral position, the red led N (4)

comes on and the engine does not start.

• If the anti-theft function has been connected before stop-

ping the engine, after the self-test it is necessa ry to e nter
the anti-theft code.

SAFETY CODE PUSH BUTTON (9)

• The anti-theft func tion is c onnected by pre ssing the pu sh but-

ton (9) (led 10 on) for at least 3 s econds before stopping the
engine (this operation must be carried out by those who know
the secret code). If the push button (9) is pressed more than
once, the function is connected and disconnected in se­quence, with the led (10) coming on and going out alternately.

REV

RWA12440

INSTRUMENTS AND CONTROLS

FWD

N

4

15

+

-

10

+

-

• After the engine sta rt and the self-test phase , if the anti-

theft function has been previously connected (led 10 on),
the secret code must be entered by keying the figures in
one by one with the UP/DOWN buttons, while the push
button 12 (DIM) must be used to confirm the entries.

• After the entry of the correct safety code and the succes-

sive acoustic confirmation, the anti-theft function is auto­matically excluded (led 10 off); to connect this function
again, press the push button (9) before stopping the en­gine.

• The anti-theft code is made up of 4 digits and is connected

with the S/N stamped on the casing. The digits are selected by
means of the UP/DOWN buttons (09) and each digit is con­firmed with the button 12 (DIM). After the 4
confirmed, the electronic system acquires the code with 3
short b eeps (0.3 secs) and the 2
logic SA is displayed.

• If an INCORRECT digit is confirmed, (88) appears on the

display and a long beep (1 sec) is emitted; repeat the op­eration entering the right code.

nd

gear with semiautomatic

th

digit has been

RWA12450

9

12

• After five consecutive incorrect confirmations, stop the

engine and start it again.

91

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

IMPORTANT

☞

DIM PUSH BUTTON (12)

• This push button confirms and acquires the anti-theft code.

The 4 digits of the secret code must be en tered in sequence
and each selection mus t be confirmed by means of the push
button 12 (DIM).

15

• This button is used al so to adju st the lumi nous inte nsity of th e

display (15) and of the leds (day/night).
This function is available after the engine star t, the self-test
phase and the display of the 2

nd

gear.

4WD PUSH BUTTON (7)

• This button engages the 4WD in 1st and 2nd gear with the

green led (8) on.
If the 4WD is engage d in 3rd or 4th gear, the led flashes and
the function is inhibited.
If you shift down from 3rd to 2
the logic automatica ll y r ecal ls th e 4 WD func tion and the green
led stops flashing and lights up continuously.

• In case of braking in 3

ly engages the 4WD and the green led (8) lights up without
flashing.

rd

nd

gear with the button (7) o n,

or 4th gear, the logic automatical-

RWA12460

RWA12470

+

-

12

8

+

-

7

GEAR SHIFTING WITH SEMIAUTOMATIC LOGIC
(SA)

• After the engine star t, the self-test phase and the entry and

confirmation of th e antitheft code, if any, the electronic control
always sets to the 2
From the 2nd gear, with reversing gear in neutral position, it is
possible to engage the 1
tons (2 UP) and (3 DOWN); engage the forward or reverse
gear within 3 se conds after the relea se of the device prevent­ing the accidental engagement of the gears.

• If the reversing gear lever is shifted to the neutral position

(N) when the machine is moving, the electronic control
maintains the selected gear, 1
them on the display.

• If the neutral (N) position is maintained for more than 3

seconds when the machine is not moving, the system sig­nals an EMERGENCY ; the electr o ni c contr ol main tains the
selected gear (see “DEVICE PREVENTIN G THE ACCIDEN­TAL SELECTION OF THE FWD/REV GEAR”).

nd

gear with semiautomatic logic (SA).

st

, 3rd or 4th gear, by means of the but-

st

, 2nd, 3rd or 4th and shows

REV

RWA12430

2

FWD

N

1

3

+

-

92

• If the gears are shif ted at unsuitable speed, the flashing le d

IMPORTANT

☞

(13) comes on and this is signalled by a long beep (1 sec).
The electronic control does not carry out the shifting, but
stores the selection.
When the speed is opti mal, the led stops flashing and the se­lected gear is engaged.
The electronic control stores only the last selection.

• The upshifting is ca rri ed out every 1.5 s econ ds with out che ck-

ing if the speed is optimal.
If UP/DOWN is pressed for more than 5 s econds, this is con­sidered as a double selection.
Pressure on UP/DOWN for more than 0 .25 se co nds i s consid­ered a selection.

• The engaged gear is always shown on the display (15).

• The 4

th

reverse gear is always disconnected.

RWA17320

INSTRUMENTS AND CONTROLS

13

15

+

-

DEVICE PREVENTING THE ACCIDENTAL SELEC­TION OF THE FWD/REV GEAR

• With the machine at rest and reversing gear lever in neutral

position, after 3 seconds the system signals an emergency
condition and the red warning light N (4) comes on.
Press the UP/DOWN buttons again and start again within 3
seconds.

• After the engine star t, during the self-test phase and the

nd

entry of the safety code, if any, before the 2

gear is dis­played, if the reversing gear lever is accidentally set in
FWD or REV position, the logic automatically recalls the
emergency function that prevents th e accidental engage­ment from occurring again.

AUTOMATIC LOGIC PUSH BUTTON (AU)

• This function is ena bled by pressing the pu sh button 11 (AUT)

once, only with the machine at rest i n safety condition ( red led
N (4) on).
The automatic function AU is indicated by the coming on of
two red points on the display (15).
If the push button is pressed mor e than once, the function is
enabled and excluded in sequence, with the two red points
coming on and going out alternately on the display (15).

REV

RWA12490

FWD

4

N

+

-

4

15

+

-

RWA12500

11

93

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

IMPORTANT

☞

GEAR SHIFTING WITH AUTOMATIC LOGIC (AU)

• After the connection of the automatic function (AUT button 11),

the electronic control always sets on the 2
forward or reverse gear within the following three seconds.

• It is possible to carry out the forced engagement of the 1

by means of the buttons DOWN (3) or KICK DOWN, while con­trolling the optimal rpm. After the forced engagement of the 1st
forward or reverse gear, the logic AU will carry out the auto­matic shifting from 1

st

to 4th forward gear or from 1st to 3
verse gear, with successive automatic shifting to the 2
forward or reverse gear.

• The engaged gear is always shown on the display (15).

• The 4

th

reverse gear is always disconnected.

• If the neutral (N) position is maintained for more than 3

seconds when the machine is not moving, the system sig­nals an EMERGENCY ; the electr o ni c contr ol main tains the
preselected gea r (see “DEVICE PREVENTING THE ACCI­DENTAL SELECTION OF THE FWD/REV GEAR”).
Even the forced 1

st

gear remains preselected.

• In case of damage to the solenoid valve of the 2

gear (signalled by 3 long beeps (1 sec) and by the flashing
of the figure message on the display (15)), the system
passes directly from automatic (AU) to semiautomatic
(SA) logic.

nd

gear; engage th e

st

nd

or 3

gear

rd

re-

nd

rd

REV

RWA12510

FWD

15

N

+

-

3

11

FWD/REV REVERSAL WITH (AU) AND (SA) LOGIC

• The FWD/REV reversal is carri ed out in 1

must take place in the shortest possible time.
The reversal is indicated by the coming on of the led F (5) or R
(6).

• It is possible to stop in the neutral position (N) for a while.

• Reversal requested in 3

timal rpm the 2

nd

rd

and 4th forward gear (FWD): with op-

gear is engaged immediately and the reverse
soon afterwards. If the r pm is not optimal, the led (13) starts
flashing and this is signalled by a long beep (1 sec.).
The electronic control d oes not carr y out the reversal and the
selection is stored.
When the optimal rp m is reached, the flashing led goes out,

nd

the 2

gear is engaged immediate ly and the reverse soon af-

terwards.

• With the (SA) logic, the UP/DOWN button cannot be operate d

until the reversal has been carried out.
One selection only is stored.

• Carry out reversals in the 3

rd

and 4th gear only in case of

emergency.

st

and 2nd gear and

REV

RWA12520

FWD

5

13

N

+

-

6

94

KICK-DOWN FUNCTION FOR 1st AND 2nd GEAR

IMPORTANT

☞

ONLY

• A pulse push button (1) posit ioned on the front loade r control

lever and connected to the electronic co ntrol engages the 1
gear from the 2nd or the 2nd from the 1st and maintains the se­lected gear.
With the semiautomati c logic (SA), it is possible to shift from

st

nd

to 2

1
With the automatic log ic (AU) it is only possible to shift down
from 2

• If the KICK DOWN function is selected - 1

electronic control verifi es the optimal r pm for the shifting (pr o­grammable).
When the r pm is not optimal, the flashing led (13) comes o n
and a long beep (1 sec) is emitted.
When the optimal rpm has been reached, the led goes out and
the 1

• If the KICK DOWN function is selected - 2

engagement of the 2

• The functions of the U P/DOWN button override the functions

of the KICK DOWN button.
The electronic control ac quires a differentiated selec tion if be­tween two selections a mi ninum time of 0.5 seco nds elapses
(the selections are not simultaneous).

gear and from 2nd to 1st gear.

nd

st

to 1

gear.

st

gear is engaged.

nd

gear takes place immediately.

st

from 2nd gear - the

nd

from 1

st

gear - the

INSTRUMENTS AND CONTROLS

A

A

st

1

RWA12530

13

+

-

RWA12480

DECLUTCH FUNCTION FOR THE 1st AND 2nd
GEAR ONLY

• A state button (1) positio ned on the front loader control lever

and connected to the electronic cont rol is used to decl utch in

st

and 2nd gear only.

1
The DECLUTCH function r emains in op eration as long as the
state button remains pressed.

• If the machine is run with speed exceeding the optimal

rpm, the flashing led (13) comes on, a long beep (1 sec) is
emitted and the electronic control engages the 3rd gear
with semiautomatic logic.

2

RWA31310

13

+

-

RWA12480

95

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

DIAGNOSTI C FUNCTION FOR SERIOUS ANOMA­LIES - MACHINE NOT WORKING

Condition either during the self-test phase and during operation.

⇒ Red alarm led (14) permanently on
⇒ 3 long beeps (1 sec)
⇒ Figure message on the display (15)
⇒ All solenoid valves at rest.

This takes place due to high oil temperature, low pressure of the
transmission oil, voltage below 7 volts, electronic card anomaly.

CAUTION

• When a figure code appears on the display, contact your

Komatsu Utility Dealer or an Komatsu Utility authorized
repair shop for the necessary checks and repairs.

DIAGNOSTIC FUNCTION FOR ANOMALIES - MA­CHINE WORKING

Condition during the self-tes t phas e.

⇒ Red alarm led (14) flashing.
⇒ 3 long beeps (1 sec).
⇒ Figure message on the display (15).

Condition during operation.

⇒ Red alarm led (14) flashing.
⇒ 3 long beeps (1 sec).
⇒ Figure message flashing on the display (15) as an alterna-

tive to the indication of the engaged gear.

RWA12550

RWA12550

14

14

15

+

-

15

+

-

• In case of damage to the gear clutch pressure sensors,

the system does not engage the clutches corresponding

nd

to the damaged sensors. In case of damage to the 2

rd

gear clutch pressure sensors, the system passes auto-

3

and

matically from the automa tic logic AU to the semiautomat­ic logic SA.

• Engine start:

In case of damage to the 2
tronic control takes the 1
case of damage to the 2

nd

gear solenoid valve, the elec-

st

gear as point of reference. In

nd

or 3rd gear solenoid valve, the
system passes automatically from the automatic logic AU
to the semiautomatic logic SA.

• In case of damage to the RPM sensor , the shifting with the

automatic logic AU cannot take place any more.

CAUTION

• When a figure code appears on the display, contact your

Komatsu Utility Dealer or an Komatsu Utility authorized
repair shop for the necessary checks and repairs.

96

INSTRUMENTS AND CONTROLS

DANGER

2 - STEERING SELECTOR UNIT

• The selection of the crab steering must be carried out with

the machine at rest and only in 1
selection of the all- wheel steer ing can b e performed even
with the machine moving and only in 1

• When the engine is started, th e two-wheel steering is au-

tomatically selected. If the acoustic alarm sounds when
the machine is restar ted, this means tha t the rear wheels
are not aligned. The misalignment of the rear wheels is
signalled also on the display (17) positioned of the front
dashboard, through the a lternate pre sence of the s ymbols
( and ) “see Fig. a”. Turn the steering wheel
clockwise or anticlockwise until the rear wheels are
aligned, which is signalled by the coming on of the green
warning light (A) and by the interruption of the alarm.
When the rear wheels are aligned, the symbols
( and ) disappear, while the speedometer (km/h
or MP/h) is displayed again . “see Fig. b”.

• Every time a steering soleno id valve is powered, its cor-

rect operation is automatic ally tested: if there is a shor t
circuit or an open circuit, a signal on the display (17) and
the acoustic alarm inform the operator that there is a f ail­ure of the solenoid valve in question.
For further details, see “3.3.1 FRONT INSTRUMENTS (pos.
17 ELECTRONIC DISPLAY)”.

st

and 2nd gear, while the

st

, 2nd and 3rd gear.

a

CHECK

b

000KM/h

CHECK

SERVICE

17

REAR

AXLE

A

17

SERVICE

CHECK

000MP/h

SERVIC

17

E

2

RWA28440

A

RWA28450

This is a contr ol with coupled mi croswitches and is u sed to se­lect the steering mode tha t is most suitable for the conditions of
the ground and the type of work to be pe rformed. The selec tion
is obtained by pressing two couple d switches at the same time,
with consequent c om in g o n o f th e corresponding LED. This sys­tem makes it possible to switch over from crab steering to all­wheel steering and vice versa, by pressing button ”1”, which cor­responds to the two-wheel steer ing, and the button correspo nd­ing to the desired steering mode at the same time (”button 3” for
crab steering and ”button 2” for all-wheel steering).
On the other hand, it is pos sible to switch over from crab or all­wheel steering to two-wheel steering by simply pressing ”button
1”, which corresponds to the two-wheel steering (see Fig. c).
The selected steeri ng mode is act ivated onl y wh en th e fr ont an d
rear wheels are aligned (automatic wheel alignment).
If you switch over from one steering mod e to the other while th e
wheels are being aligned, the acoustic alarm keeps sounding
until the front or rear wheels are perfectly aligned.
The alignment of the wheels is indicated also on the display (17)
positioned on the upper part of the front dahsboard.

c

CHECK

SERVICE

2 1 3

RWA27670

97

INSTRUMENTS AND CONTROLS

IMPORTANT

☞

The display (17) indicates which wheels must be aligned through
the relevant symbols:

- Front wheels misaligned (see Fig. d).

- Rear wheels misaligned (see Fig. e).
Once the wheels are aligne d, the relevant symbols go out and

the acoustic alarm stops.

d

FRON

CHECK

T AXLE

e

REAR AXLE

CHECK

17

SERVICE

RWA34780

17

SERVICE

• In case of repl acement of the rear axle, th e monitor, the

potentiometer, the sensor or any other component of the
steering system, it is necessary to carry out the alignment
of the rear wheels, by proceeding as follows:

- turn the steering wheel clockwise and anticlockwise,

until the rear wheels are aligned;

- before checking the alignment of the wheels, stop the

machine;

- press the push buttons (1-2-3) shown in Fig. (c) at the

same time;

- keeping the th ree buttons presse d, tu rn the key to p osi-

tion «I» to activate the electric signal;

- after a few seconds the writing “KOMATSU” will appear

on the monitor (17), followed by the symbol that indi­cates the alignment of the rear wheels ( );

- press the push button (1) shown in Fig. (c);

- the co rrect alignment o f the rear wheel s is signalled by

the coming on of the green warning light (A) and by the
display of the symbols “KM/h or MP/h” on the monitor
(17), as shown in Fig. (b).

c

b

CHECK

CHECK

000KM/h

SERVICE

17

SERVICE

2 1 3

A

CHECK

000MP/h

SERVICE

RWA28480

RWA27670

17

A

RWA28450

98