Komatsu Utility WB97S-5 Manual

Operation & Maintenance
Manual
WEAM007600
BACKHOE-LOADER
WB97S-5
SERIAL NUMBER
WB97S-5 F5 3 and up
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.
ATTENTION
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FOREWORD
1
1.1 FOREWORD
qThis manual has been produced by Komatsu Utility S.p.A. in order to supply their customers with all the
necessary information on the machine and the safety regulations related to it, together with the use and
maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and
to keep the machine efficient over time.
qThe operation manual, together with the spare parts catalogue, is an integral part of the machine and must
accompany it, even when it is resold, until its final disposal.
qThe manual must be handled with the greatest care and always kept on board the machine, so that it can be
consulted at any moment; it must be placed in the appropriate compartment behind the seat, where also the
ownership documents and the logbook are usually kept (see "3.5.9 TECHNICAL DOCUMENTATION").
qThis manual must be given to the persons who have to use the machine and carry out the routine maintenance
operations; they must read the contents carefully more than once, in such a way as to clearly understand what
are the correct operating conditions and the dangerous conditions that must be avoided.
In case of loss or damage, request a new copy to Komatsu or your Komatsu Dealer.
qThe illustrations contained in this manual may represent machine configurations available on request.
The machines are constantly upgraded in order to increase their efficiency and reliability; this manual sums up
all the information regarding the state of the art at the moment when the machine is launched on the market.
Contact your Komatsu Dealer for updated information.
qPunctual periodic annotations regarding the maintenance operations that have been carried out are important to
have a clear prospect of the situation and to know exactly what has been done and what has to be done after the
next maintenance interval. Therefore, it is advisable to consult both the hour meter and the maintenance plan
frequently.
qKomatsu Dealers have gathered a considerable amount of experience over years of work in close contact with
the users.
If more information is needed, do not hesitate to contact your Komatsu Dealer: he always knows how to get the
best performance from the machine, he can recommend the equipment that is most suitable for specific needs
and can provide the technical assistance necessary for any change that may be required to conform the
machine to the safety standards and traffic rules.
Komatsu Dealers also provide assistance for the supply of original Komatsu spare parts, which alone guarantee
safety and interchangeability.
qThe table included in this manual must be filled in with the machine data, which are the data that must always be
indicated to the Dealer when requiring assistance and ordering spare parts.
CAUTION
qThe incorrect use of the machine and inappropriate maintenance operations may cause serious injury
and even death.
qOperators and maintenance personnel must carefully read this manual before using the machine or
performing maintenance operations.
qSome actions involved in the operation and maintenance of the machine may cause serious injury or
even death, if they are not performed in compliance with the instructions given herein.
qThe procedures and precautions described in this manual are valid for application to the machine only
when it is used correctly.
If the machine is used for any purpose or in any way other than those described herein, the operator
shall be responsible for his own safety and for the safety of any other person involved.
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INFORMATION ON SAFETY
2
1.2 INFORMATION ON SAFETY
Many accidents are caused by insufficient knowledge of and failure to comply with the safety regulations
prescribed for the maintenance operations that must be performed on the machine.
In order to avoid accidents, before starting work and before carrying out any maintenance operation, carefully read
and be sure to understand all the information and warnings contained in this manual and given on the plates
applied onto the machine. To allow the operator to use the machine in total safety, precautions and safety plates
are described in this manual and applied to the machine in order to supply information regarding situations that
involve potential risks and the measures that may be adopted to avoid such situations.
Terminology used in the signs
The following terms are used in the signs to inform the user that there is a situation of potential danger that may
cause injury or damage.
In this manual and in the plates applied to the machine the following terms are used to indicate potential dangers.
DANGER
qIndicates a situation of imminent danger that, if not avoided, may cause serious injury and even death.
The use of this term must be limited to situations of extreme danger.
WARNING
qIndicates a situation of potential danger that, if not avoided, may cause serious injury and even death.
CAUTION
qIndicates a situation of potential danger that, if not avoided, may cause moderate injury. This term can
also be used as a warning in case of dangerous procedures.
Other terms used in the signs
In addition to those indicated above, the following warning terms are used to recommend the precautions to be
taken to protect the machine or to supply useful information.
IMPORTANT
qThis term is used to indicate precautions that must be taken in order to avoid actions that may reduce
the life of the machine.
NOTE
qThis word is used to indicate a useful piece of information.
Komatsu cannot reasonably predict every circumstance that might involve a potential hazard during the operation
or maintenance of the machine; for this reason, the safety messages included in this manual and applied onto the
machine may not include all possible safety precautions.
If all the procedures and operations prescribed for this machine are kept to, you can be sure that the operator and
the persons in the vicinity will work in total safety, with no risk of damaging the machine. In case of doubt regarding
the safety measures necessary for some procedures, contact Komatsu or your local Dealer.
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INFORMATION ON SAFETY
3
DANGER
qBefore starting any maintenance operation, position the machine on firm and level ground, engage the
safety locks of the equipment and of the controls, stop the engine and apply the parking brake.
DANGER
qTo make the information clearer, some illustrations in this manual represent the machine without safety
guards. Do not use the machine without guards and do not start the engine when the hood is open,
unless this is expressly prescribed for certain maintenance operations.
WARNING
qIt is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be
held liable for any personal injury, or damage to property or the machine, if this has been tampered with
by modifying the standard setting of the hydraulic system.
WARNING
qBefore carrying out any electric welding operation, disconnect the battery and the alternator. (See
"2.8.13 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR").
WARNING
qInstall only authorized additional equipment (See "6.1 AUTHORIZED OPTIONAL EQUIPMENT").
WARNING
qThe machine can travel on roads only if equipped with suitable lighting, signalling and safety devices
and if this type of use is authorized by the logbook.
Before travelling on roads, make sure that the equipment with which the machine is provided is
homologated and that the safety locks are correctly engaged.
DANGER
qIt is absolutely forbidden to manoeuvre the machine while standing on the ground.
Each operation must be carried out by the operator correctly seated in the driving position.
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INTRODUCTION
4
1.3 INTRODUCTION
1.3.1 INTENDED USES
The Komatsu BACKHOE LOADERS described in this manual have been designed and constructed to be used
mainly with the following functions:
qLOADER
qEXCAVATOR
Through the installation of optional equipment, the machine can also be used for the following applications:
qHANDLING OF MATERIALS (4IN1 BUCKET - PALLET FORKS)
qSNOWPLOUGH (ANGLEDOZER BLADE - SNOWPLOUGH)
qDEMOLITION (HAND HAMMER - HAMMER ON THE BACKHOE)
qDITCH CLEANING AND DIGGING (SPECIAL BUCKETS)
1.3.2 IMPROPER OR UNAUTHORIZED USE
CAUTION
qThis paragraph describes some improper or unauthorized uses of the machine; since it is impossible to
predict all possible improper uses, if the machine is going to be used for particular applications, contact
your Komatsu Dealer before carrying out the work.
IMPORTANT
qThe instructions regarding the authorized optional equipment are given in the relevant operation and
maintenance manuals; if the equipment is supplied by Komatsu, these publications are enclosed to this
manual.
qThe instructions regarding the assembly of the authorized equipment, the controls requiring special
arrangements on the machine and the hydraulic couplings necessary for the operation of the equipment
are grouped in the final section of this manual.
Komatsu BACKHOE LOADERS are constructed exclusively for the handling, excavation and treatment of inert
materials; therefore, the following uses are absolutely forbidden:
qUSE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS.
qUSE OF THE MACHINE FOR LIFTING PERSONS OR OBJECTS.
qTRANSPORTATION OF PERSONS even if they are in the operator’s cab.
qTRANSPORTATION OF CONTAINERS with fluids, flammable fluids, loose material, without the appropriate
slinging equipment.
qTRANSPORTATION AND LIFTING (EVEN IF IN EXCEPTIONAL CASES) OF EQUIPMENT OR MATERIALS
THAT PROTRUDE FROM THE BUCKET OR ARE NOT SECURED TO THE BUCKET BY MEANS OF ROPES
OR CHAINS.
qUSE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
qUSE OF THE MACHINE FOR TOWING DAMAGED VEHICLES ON ROADS.
qUSE OF THE MACHINE FOR LIFTING DAMAGED VEHICLES.
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INTRODUCTION
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1.3.3 MAIN CHARACTERISTICS
qSimple and easy operation.
qServo-assisted steering with priority hydraulic system.
qThree steering modes selected by means of microswitches in pairs.
- Two-wheel steering (2WS)
- Four-wheel steering (4WS ROUND)
- Four-wheel steering (4WS CRAB)
qGearshift with electronic gear selection through solenoid-operated actuators and hydraulic converter; reverse
gear and speed change with controls on a single lever.
qLoader control through a single servo lever ensuring also combined movements that can be modulated
proportionally and continually.
qBackhoe controls with two servo levers ensuring also combined movements that can be modulated
proportionally and continually.
qComplete series of instruments visible from the two operating positions (loader or backhoe).
qSeparate accelerator controls for the two operating positions.
qFoot brake control.
qEasy maintenance with simplified intervals.
qAutomatic engagement and disengagement 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 carefully for the first 100 hours, in order to ensure proper running-in of the
various components.
If the machine is subjected to an excessive work load at the beginning of its service life, its productivity and
functionality will be untimely reduced.
Every new machine must be used carefully, paying special attention to the following indications:
qAfter the start, let the engine idle for 5 minutes, in such a way as to warm it up gradually before actual operation.
qAvoid operating the machine with the limit loads allowed or at high speed.
qAvoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals.
qAfter the first 250 hours of use, carry out the following operations, in addition to those to be performed every 250
hours:
1 - Change the hydraulic transmission oil and filter.
2 - Change the differential unit oil (front and rear axle).
3 - Change the final reduction gear oil (front and rear axle).
4 - Change the hydraulic circuit oil filter.
SYNTHETIC BIODEGRADABLE OIL TYPE HEES
On machines in which the synthetic biodegradable oil type HEES is used, the following operations are to be
performed together with the standard maintenance operations.
qAfter the first 50 hours of operation, change the hydraulic circuit drain filter.
qAfter the first 500 hours of operation, change the hydraulic circuit oil.
IMPORTANT
qWhen changing the oil filters (cartridges), check their innner part to make sure that there are no
deposits.
If abundant deposits are observed, find out what may have caused their accumulation before starting
the machine.
qThe number of operation hours is indicated by the hour meter.
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PRODUCT IDENTIFICATION
6
1.4 PRODUCT IDENTIFICATION
The Komatsu backhoe loader and its main components are identified by serial numbers stamped on the identification
plates. The serial number and the identification numbers of the components are the only numbers that must be
indicated to the Dealer when requiring assistance and ordering spare parts.
1.4.1 MACHINE IDENTIFICATION NUMBER
(PIN)
The machine identification number "PIN" is stamped on the right
side of the frame front.
1.4.2 MACHINE IDENTIFICATION PLATE
AND PRODUCT IDENTIFICATION
NUMBER (PIN)
(alternatively for some markets)
The Komatsu BACKHOE LOADERS described in this manual are
CE marked, in fact they are in full compliance with the EU
harmonised standards. The Product Identification Number (PIN) is
stamped on the lower part of the plate. The customer must be able to
indicate the PIN at any time, that is why it must compulsorily be
written in the following table. The plate with the CE marking is
applied inside the cab, on the left vertical wall of the frame, at the
height of the brake pedals.
RKAB5970
RKAB2680
37A-98-11820
MODELLO - MODEL
TYP - MODELE
kg
kw
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) - ITALY
MATRICOLA N˚ - SERIAL N˚
FABR. NR. - SERIE NR.
ANNO - YEAR
BAUJAHR - ANNEE
MASSA TOTALE - TOTAL WEIGHT
GESAMTGEWICHT - POIDS TOTAL
POTENZA MOTORE - ENGINE POWER
LEISTUNG - PUISSANCE MOTEUR
Product Identification Number
PIN
RKA14970
MODEL
kg
kw
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) - ITALY
SERIAL N˚
YEAR
TOTAL WEIGHT
ENGINE POWER
Product Identification Number
PIN
37A-98-11820
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PRODUCT IDENTIFICATION
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1.4.3 MACHINE IDENTIFICATION PLATE
AND PRODUCT IDENTIFICATION
NUMBER (PIN)
The Komatsu BACKHOE LOADERS described in this manual are
CE marked, in fact they are in full compliance with the EU
harmonised standards.
The Product Identification Number (PIN) is stamped on the lower
part of the plate. The customer must be able to indicate the PIN at
any time, that is why it must compulsorily be written in the
following table. The plate with the CE marking is applied inside
the cab, on the left vertical wall of the frame, at the height of the
brake pedals.
RKAB2680
NUMERO DI OMOLOGAZIONE
HOMOLOGATION NUMBER
TIPO
TYPE - MODEL
MASSA TOTALE AMMISSIBILE
TOTAL MASS WEIGHT
CARICO AMMISSIBILE ASSE ANT.
WEIGHT FRONT AXLE
CARICO AMMISSIBILE ASSE POST.
WEIGHT REAR AXLE
Product Id ntification Numb r
PIN
DA
FROM
DA
FROM
DA
FROM
A
TO
A
TO
A
TO
- Massa rimorchiabil : non atto
POTENZA MOTORE
MATRICOLA
SERIAL NUMBER
ANNO
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A. 36025 NOVENTA VIC. (VI) -ITALY
W
kg
kg
kg
kg
kg
kg
37A-98-11840
HOMOLOGATION NUMBER
TYPE
TOTAL MASS WEIGHT
WEIGHT FRONT AXLE
WEIGHT REAR AXLE
Product Id ntification Numb r
PIN
TO
TO
TO
- Towabl w ight: not suitabl
ENGINE POWER
SERIAL NUMBER
YEAR
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A. 36025 NOVENTA VIC. (VI) -ITALY
W
kg
kg
kg
kg
kg
kg
37A-98-11840
FROM
FROM
FROM
RKA16060
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PRODUCT IDENTIFICATION
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1.4.4 ENGINE SERIAL NUMBER AND
EXHAUST GAS EMISSION PLATE
The identification plate (1) is fixed above the engine head and
indicates the engine model, total displacement and serial number.
The identification plate (2) is fixed to the left side of the engine
block, bears the Manufacturer’s mark and contains the following
data:
1 - Engine type
2 - Engine family
3 - Serial number
4 - EC Type Approval
5 - EPA
The serial number (3) is also stamped on the right side of the
cylinder block, on the upper part of the oil cooling heat exchanger.
1.4.5 FRONT AXLE SERIAL NUMBER
The serial number of the rear axle is stamped on the plate
positioned on the right side of the axle body.
RKAB2690
1
RKAB2700
2
RKAB2710
3
RKAB5980
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PRODUCT IDENTIFICATION
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1.4.6 REAR AXLE SERIAL NUMBER
The serial number is stamped on the plate positioned on the left
side of the axle body.
1.4.7 TRANSMISSION SERIAL NUMBER
The transmission serial number is stamped on the plate postioned
on the right side of the transmission case.
1.4.8 CAB SERIAL NUMBER
The cab serial number is stamped on the plate postioned on the
left side of the rear wall.
RKAB5990
RKAB2750
RKAB2740
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PRODUCT IDENTIFICATION
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1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS
Machine no. Mod.
Front axle no.
Rear axle no.
Transmission no.
Dealer:
Address:
Tel.
Contact person:
NOTES:
Cab no.
Product identification number (PIN)
Engine no.
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TABLE OF CONTENTS
11
TABLE OF CONTENTS
FOREWORD
1.1 FOREWORD.......................................................................................................................................... 1
1.2 INFORMATION ON SAFETY................................................................................................................ 2
1.3 INTRODUCTION ................................................................................................................................... 4
1.3.1 INTENDED USES .................................................................................................................... 4
1.3.2 IMPROPER OR UNAUTHORIZED USE.................................................................................. 4
1.3.3 MAIN CHARACTERISTICS...................................................................................................... 5
1.3.4 RUNNING-IN............................................................................................................................ 5
1.4 PRODUCT IDENTIFICATION ............................................................................................................... 6
1.4.1 MACHINE IDENTIFICATION NUMBER (PIN) ......................................................................... 6
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
(alternatively for some markets) .............................................................................................. 6
1.4.3 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN).... 7
1.4.4 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE................................... 8
1.4.5 FRONT AXLE SERIAL NUMBER............................................................................................. 8
1.4.6 REAR AXLE SERIAL NUMBER............................................................................................... 9
1.4.7 TRANSMISSION SERIAL NUMBER........................................................................................ 9
1.4.8 CAB SERIAL NUMBER............................................................................................................ 9
1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS .................................................................... 10
SAFETY AND ACCIDENT PREVENTION
2.1 SAFETY, NOISE AND VIBRATION PLATES....................................................................................... 20
2.1.1 POSITION OF THE SAFETY PLATES .................................................................................... 20
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS......................................................................... 22
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB .......................................... 28
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED ................................................ 29
2.2 GENERAL PRECAUTIONS.................................................................................................................. 30
2.2.1 GENERAL SAFETY RULES .................................................................................................... 30
2.2.2 SAFETY DEVICES AND GUARDS.......................................................................................... 30
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS............................................................. 30
2.2.4 UNAUTHORIZED MODIFICATIONS ....................................................................................... 31
2.2.5 LEAVING THE OPERATOR’S SEAT....................................................................................... 31
2.2.6 GETTING ON AND OFF THE MACHINE................................................................................. 32
2.2.7 CHECKING THE REAR-VIEW MIRRORS .............................................................................. 32
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL ..................................................................... 33
2.2.9 PREVENTING BURNS ............................................................................................................ 33
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER .................................................... 34
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........................................ 34
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT ........................................................................ 35
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE...................................................... 35
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT ............................................................... 35
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE................................................. 36
2.3.1 SAFETY ON THE WORK SITE................................................................................................ 36
2.3.2 FIRE PREVENTION ................................................................................................................ 36
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB ............................................. 36
2.3.4 ROOM VENTILATION ............................................................................................................. 37
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD
WIPER BLADES AND THE BULBS......................................................................................... 37
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2.4 PRECAUTIONS TO BE TAKEN DURING WORK................................................................................ 38
2.4.1 WHEN STARTING THE ENGINE............................................................................................. 38
2.4.2 RULES FOR TRAVELLING ON ROADS.................................................................................. 38
2.4.3 HAND SIGNALS....................................................................................................................... 39
2.4.4 CHECKS FOR TRAVELLING IN REVERSE............................................................................ 44
2.4.5 MOVING THE MACHINE .........................................................................................................44
2.4.6 WORKING ON SLOPES .........................................................................................................45
2.4.7 PREVENTING ELECTROCUTION .......................................................................................... 46
2.4.8 VISIBILITY................................................................................................................................ 47
2.4.9 WORKING ON ICY OR SNOW-COVERED SURFACES......................................................... 47
2.4.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT......................................... 47
2.4.11 WORKING ON LOOSE GROUND ........................................................................................... 47
2.4.12 PARKING THE MACHINE........................................................................................................ 48
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES ................................................................. 49
2.5.1 LOADING AND UNLOADING THE MACHINE ........................................................................ 49
2.5.2 TRANSPORT............................................................................................................................ 49
2.6 BATTERY.............................................................................................................................................. 50
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY............................................. 50
2.6.2 STARTING WITH BOOSTER CABLES ................................................................................... 50
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY............................................................................... 51
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE................................................................. 52
2.8.1 WARNING PLATES.................................................................................................................. 52
2.8.2 TOOLS ..................................................................................................................................... 52
2.8.3 PERSONNEL............................................................................................................................ 53
2.8.4 EQUIPMENT ........................................................................................................................... 53
2.8.5 WORKING UNDER THE MACHINE ........................................................................................ 53
2.8.6 KEEPING THE MACHINE CLEAN .......................................................................................... 54
2.8.7 USE OF THE ENGINE DURING MAINTENANCE................................................................... 54
2.8.8 PERIODICAL CHANGE OF THE SAFETY RELATED PARTS................................................ 54
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
OR INSPECTION .................................................................................................................... 55
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP ...................................... 56
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR........................................................ 56
2.8.12 USING LAMPS......................................................................................................................... 56
2.8.13 PRECAUTIONSTOBETAKENWHENHANDLINGTHEBATTERYANDTHEALTERNATOR 57
2.8.14 PRECAUTIONS CONCERNING THE STARTER.................................................................... 57
2.8.15 HANDLING HIGH-PRESSURE PIPES..................................................................................... 58
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH- PRESSURE SYSTEMS ....... 58
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES
AND PRESSURES...................................................................................................................58
2.8.18 HYDRAULIC ACCUMULATOR ................................................................................................ 59
2.8.19 COOLING FAN AND FAN BELT .............................................................................................. 59
2.8.20 WASTE MATERIALS................................................................................................................ 59
2.8.21 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS........................ 60
2.8.22 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES ......................................... 60
2.8.23 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE............ 61
2.8.24 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL
TYPE «HEES».......................................................................................................................... 61
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DESCRIPTION AND USE OF THE MACHINE
3.1 SAFETY LOCKS................................................................................................................................... 64
3.1.1 FRONT LOADER LOCKS ........................................................................................................ 64
3.1.2 BACKHOE LOCKS................................................................................................................... 66
3.2 GENERAL VIEWS................................................................................................................................. 68
3.2.1 FRONT GENERAL VIEW.........................................................................................................68
3.2.2 BACKHOE GENERAL VIEW.................................................................................................... 69
3.2.3 CAB INSIDE GENERAL VIEW................................................................................................. 70
3.3 INSTRUMENTS AND CONTROLS....................................................................................................... 71
3.3.1 FRONT INSTRUMENTS ..........................................................................................................71
3.3.2 SIDE INSTRUMENTS .............................................................................................................. 76
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER .......................................... 84
3.3.4 CAB SWITCHES AND ELECTRIC ACCESSORIES................................................................ 86
3.3.5 MACHINE CONTROLS............................................................................................................ 89
3.3.6 ADJUSTING THE CONTROLS ............................................................................................... 110
3.4 FUSES AND RELAYS........................................................................................................................... 113
3.4.1 CENTRAL UNIT FUSES – RELAYS AND ENGINE LINE........................................................ 113
3.4.1.1 FUSES .................................................................................................................... 113
3.4.1.2 RELAYS.................................................................................................................. 115
3.4.2 VENTILATION, HEATING AND AIR CONDITIONING FUSES AND RELAYS........................ 116
3.4.2.1 FUSES .................................................................................................................... 116
3.4.2.2 RELAYS.................................................................................................................. 116
3.5 GUARDS, CAB AND DRIVER’S SEAT ................................................................................................ 117
3.5.1 ENGINE HOOD........................................................................................................................ 117
3.5.2 CAB .......................................................................................................................................... 118
3.5.3 VENTILATION AND HEATING ................................................................................................ 121
3.5.4 AIR CONDITIONER (if installed).............................................................................................. 122
3.5.5 SEAT ........................................................................................................................................ 124
3.5.5.1 SEAT (STANDARD) ............................................................................................... 124
3.5.5.2 SEAT (OPTIONAL) ................................................................................................ 125
3.5.6 SAFETY BELT.......................................................................................................................... 126
3.5.7 FIRE EXTINGUISHER ............................................................................................................ 126
3.5.8 FIRST AID KIT ......................................................................................................................... 126
3.5.9 TECHNICAL DOCUMENTATION ............................................................................................ 126
3.5.10 STORAGE COMPARTMENT .................................................................................................. 127
3.6 USE OF THE MACHINE........................................................................................................................ 128
3.6.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE................................... 128
3.6.1.1 VISUAL CHECKS.................................................................................................... 128
3.6.1.2 OPERATIONAL CHECKS ...................................................................................... 129
3.6.2 STARTING THE ENGINE ........................................................................................................ 130
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES ................... 130
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES................................. 131
3.6.3 WARMING THE ENGINE......................................................................................................... 132
3.6.4 HEATING THE HYDRAULIC OIL............................................................................................. 132
3.6.5 HOW TO MOVE THE MACHINE ............................................................................................. 133
3.6.5.1 ENGAGING THE FOUR-WHEEL DRIVE ............................................................... 134
3.6.5.2 WORKING ON SLOPES ........................................................................................ 135
3.6.5.3 MAXIMUM IMMERSION DEPTH............................................................................ 136
3.7 PARKING THE MACHINE .................................................................................................................... 137
3.7.1 PARKING ON LEVEL GROUND.............................................................................................. 137
3.7.2 PARKING ON SLOPES............................................................................................................ 138
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3.8 STOPPING THE ENGINE ..................................................................................................................... 139
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES ................................................................. 140
3.9.1 LOADING AND UNLOADING THE MACHINE......................................................................... 140
3.9.2 TRANSPORT............................................................................................................................ 141
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON ................................................................... 142
3.10.1 FUEL AND LUBRICANTS........................................................................................................ 142
3.10.2 COOLANT ................................................................................................................................ 142
3.10.3 BATTERY................................................................................................................................. 143
3.10.4 OTHER PRECAUTIONS .......................................................................................................... 143
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK ...................................................... 143
3.11 PRECAUTIONS TO BE TAKEN AT THE END OF THE WINTER........................................................ 144
3.12 USING THE MACHINE AS A LOADER................................................................................................ 145
3.12.1 BUCKET POSITION INDICATOR............................................................................................ 145
3.12.2 ORGANIZING THE WORK AREA............................................................................................ 145
3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL......................................................... 146
3.12.2.2 LOADING OPERATIONS ON SLOPES.................................................................. 147
3.12.3 CHANGING THE STANDARD FRONT BUCKET .................................................................... 147
3.13 USING THE MACHINE AS AN EXCAVATOR...................................................................................... 148
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT 148
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS............................................... 149
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS ........................................................................ 150
3.13.4 DIGGING METHOD.................................................................................................................. 151
3.13.4.1 CHANGING THE BACKHOE BUCKET................................................................... 152
3.14 LONG PERIODS OF INACTIVITY ........................................................................................................ 153
3.14.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY.................................. 153
3.14.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY..................................... 154
3.14.3 MAINTENANCE DURING A PERIOD OF INACTIVITY ........................................................... 154
3.14.4 RESTARTING THE ENGINE.................................................................................................... 155
3.14.5 AFTER THE PERIOD OF INACTIVITY.................................................................................... 155
3.15 TROUBLESHOOTING .......................................................................................................................... 156
3.15.1 HOW TO REMOVE THE MACHINE......................................................................................... 156
3.15.2 AFTER THE FUEL HAS RUN OUT.......................................................................................... 156
3.15.3 IF THE BATTERY IS DOWN....................................................................................................157
3.15.3.1 STARTING WITH BOOSTER CABLES .................................................................. 158
3.15.4 OTHER TROUBLES................................................................................................................. 159
3.15.4.1 ELECTRICAL CIRCUIT........................................................................................... 159
3.15.4.2 HYDRAULIC SYSTEM............................................................................................ 159
3.15.4.3 BRAKING SYSTEM ................................................................................................ 160
3.15.4.4 CONVERTER.......................................................................................................... 160
3.15.4.5 ENGINE................................................................................................................... 160
MAINTENANCE
4.1 GUIDE TO MAINTENANCE.................................................................................................................. 164
4.2 MAINTENANCE NOTES....................................................................................................................... 166
4.2.1 NOTES REGARDING THE ENGINE........................................................................................ 166
4.2.1.1 ENGINE OIL............................................................................................................ 166
4.2.1.2 COOLANT............................................................................................................... 166
4.2.1.3 FUEL ....................................................................................................................... 167
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM................................................................. 167
4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM.................................................................... 168
4.2.4 NOTES REGARDING LUBRICATION ..................................................................................... 168
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING.............................. 169
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4.3 FUEL, COOLANT AND LUBRICANTS................................................................................................. 170
4.3.1 LUBRICATION WITH GREASE ............................................................................................... 171
4.3.2 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS “HEES”........................... 172
4.4 DRIVING TORQUES............................................................................................................................. 173
4.4.1 STANDARD DRIVING TORQUES FOR SCREWS AND NUTS .............................................. 173
4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS ................................................. 174
4.4.3 STANDARD DRIVING TORQUES FOR HOSES WITH ORFS................................................ 174
4.5 LUBRICATION...................................................................................................................................... 175
4.5.1 LUBRICATION DIAGRAM........................................................................................................ 175
4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks) ........................................................ 176
4.5.3 LUBRICATION DIAGRAM (front bucket quick couplings)........................................................ 177
4.5.4 LUBRICATION DIAGRAM (offset device)................................................................................ 178
4.6 PERIODICAL CHANGE OF THE SAFETY RELATED COMPONENTS.............................................. 179
4.6.1 SAFETY RELATED PARTS..................................................................................................... 180
4.6.1.1 FUEL SYSTEM ....................................................................................................... 180
4.6.1.2 DELIVERY HYDRAULIC SYSTEM......................................................................... 181
4.6.1.3 FRONT LOADER HYDRAULIC SYSTEM............................................................... 182
4.6.1.4 BACKHOE HYDRALIC SYSTEM............................................................................ 183
4.6.1.5 OPERATOR’S SAFETY.......................................................................................... 184
4.7 MAINTENANCE PLAN.......................................................................................................................... 185
4.8 MAINTENANCE PROCEDURES.......................................................................................................... 187
4.8.1 WHEN REQUIRED................................................................................................................... 187
4.8.1.a CHECKING, CLEANING OR CHANGING THE ENGINE AIR FILTERS ................ 187
4.8.1.b CHECKING AND CLEANING THE CAB AIR FILTER ............................................ 188
4.8.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER
(only for machines with air conditioner)................................................................... 189
4.8.1.d CHECKING THE DETERGENT LEVEL IN THE WINDSHIELD WASHER
RESERVOIR........................................................................................................... 189
4.8.1.e CHECKING THE WINDSHIELD WIPER BLADES.................................................. 190
4.8.1.f LUBRICATING THE CAB DOOR HINGES............................................................. 190
4.8.1.g FUSES AND RELAYS – CHECK AND CHANGE................................................... 190
4.8.1.h BLEEDING THE BRAKING CIRCUIT..................................................................... 191
4.8.1.i CHECKING AND ADJUSTING THE WHEEL TOE-IN ........................................... 192
4.8.1.j CHECKING THE BRAKING EFFICIENCY.............................................................. 192
4.8.1.k CHECKING AND ADJUSTING THE PARKING BRAKE......................................... 193
4.8.1.l CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE ............................. 194
4.8.1.m ADJUSTING THE AUTOMATIC RETURN-TO-DIG DEVICE OF THE FRONT
BUCKET (if installed) .............................................................................................. 194
4.8.1.n CHECKING AND ADJUSTING THE STABILIZER SLACK..................................... 195
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER.............. 196
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER........................................................... 196
4.8.2.b CHANGING THE HYDRAULIC OIL........................................................................ 196
4.8.3 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE................................... 197
4.8.3.a VARIOUS CHECKS................................................................................................ 197
4.8.3.b CHECKING THE COOLANT LEVEL....................................................................... 197
4.8.3.c CHECKING THE FUEL LEVEL............................................................................... 198
4.8.3.d CHECKING THE ENGINE OIL LEVEL ................................................................... 198
4.8.4 MAINTENANCE EVERY 10 HOURS OF OPERATION........................................................... 199
4.8.4.a LUBRICATING THE JOINTS.................................................................................. 199
4.8.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION
(Only for machines in which synthetic biodegradable oil type HEES is used).......................... 201
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4.8.6 MAINTENANCE EVERY 50 HOURS OF OPERATION ........................................................... 201
4.8.6.a CHECKING THE HYDRAULIC OIL LEVEL ............................................................ 201
4.8.6.b CHECKING THE FLUID LEVEL IN THE RADIATOR ............................................. 202
4.8.6.c CHECKING THE BRAKING SYSTEM OIL LEVEL ................................................. 202
4.8.6.d LUBRICATING THE PROPELLER SHAFTS .......................................................... 203
4.8.6.e LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING
AND THE REAR AXLE JOINTS ............................................................................. 204
4.8.6.f CHECKING THE TYRE PRESSURE...................................................................... 204
4.8.6.g DRAINING THE WATER SEPARATOR ................................................................. 205
4.8.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...................................... 206
4.8.8 MAINTENANCE EVERY 250 HOURS OF OPERATION ......................................................... 206
4.8.8.a CHECKING THE ALTERNATOR-FAN BELT.......................................................... 206
4.8.8.b CHECKING AND ADJUSTING THE A/C COMPRESSOR BELT TENSION
(only for machines with air conditioner)................................................................... 207
4.8.8.c CHECKING THE BATTERY ELECTROLYTE LEVEL ............................................ 208
4.8.8.d CHECKING THE FRONT AXLE OIL LEVELS........................................................ 209
4.8.8.e CHECKING THE REAR AXLE OIL LEVEL............................................................. 209
4.8.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL................................ 210
4.8.8.g CHECKING THE WHEEL NUT DRIVING TORQUE............................................... 210
4.8.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION
(Only for machines in which synthetic biodegradable oil type HEES is used).......................... 211
4.8.10 MAINTENANCE EVERY 500 HOURS OF OPERATION ......................................................... 211
4.8.10.a CHANGING THE ENGINE OIL ............................................................................... 211
4.8.10.b CHANGING THE ENGINE OIL FILTER.................................................................. 212
4.8.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER........................................... 212
4.8.10.d CHANGING THE FUEL FILTER............................................................................. 215
4.8.10.e DRAINING THE FUEL TANK.................................................................................. 216
4.8.10.f DRAINING THE HYDRAULIC OIL TANK
(only for machines in which synthetic biodegradable oil type HEES is used) ......... 217
4.8.10.g CLEANING THE OUTSIDE OF THE RADIATOR................................................... 218
4.8.10.h CLEANING THE OUTSIDE OF THE A/C CONDENSER
(only for machines with air conditioner) .................................................................. 219
4.8.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION....................................................... 220
4.8.11.a CHANGING THE FRONT AXLE OIL ...................................................................... 220
4.8.11.b CHANGING THE REAR AXLE OIL......................................................................... 221
4.8.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL............................................ 222
4.8.11.d CHANGING THE HYDRAULIC TRANSMISSION OIL FILTER .............................. 223
4.8.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION....................................................... 224
4.8.12.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER......... 224
4.8.12.b CHANGING THE COOLANT ................................................................................. 226
4.8.12.c CHANGING THE BRAKING SYSTEM OIL............................................................. 227
4.8.12.d CHECKING THE ALTERNATOR AND THE STARTER ......................................... 228
4.8.12.e CHANGING THE ALTERNATOR BELT.................................................................. 228
4.8.12.f CHECKING THE A/C COOLING GAS QUANTITY
(only for machines with air conditioner)................................................................... 228
4.8.13 MAINTENANCE EVERY 3000 HOURS OF OPERATION....................................................... 229
4.8.13.a CHECKING THE ENGINE RETAINING SCREWS AND DAMPING ELEMENTS .. 229
4.8.13.b CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE
AND THE INJECTION TIMING ADVANCE............................................................. 229
4.8.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION....................................................... 230
4.8.14.a CHANGING THE A/C DEWATERING FILTER
(Only for machines with air conditioner) ................................................................. 230
4.8.14.b CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR
(Only for machines with air conditioner) ................................................................ 230
4.8.14.c CHANGING THE ENGINE THERMOSTATIC VALVE............................................ 230
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TECHNICAL SPECIFICATIONS
5.1 TECHNICAL DATA............................................................................................................................... 232
5.1.1 STANDARD OVERALL DIMENSIONS .................................................................................... 232
5.1.1.1 OVERALL DIMENSIONS WITH STANDARD ARM................................................ 232
5.1.1.2 OVERALL DIMENSIONS WITH TELESCOPIC ARM............................................. 232
5.1.2 TECHNICAL CHARACTERISTICS .......................................................................................... 233
5.1.3 LIFTING CAPACITIES ............................................................................................................. 235
5.1.3.1 SYMBOL TABLE..................................................................................................... 235
5.1.3.2 LIFTING CAPACITIES (STANDARD ARM)............................................................ 236
5.1.3.3 LIFTING CAPACITIES (BOOM WITH OFFSET DEVICE)...................................... 237
AUTHORIZED OPTIONAL EQUIPMENT
6.1 AUTHORIZED OPTIONAL EQUIPMENT ............................................................................................. 240
6.1.1 PRECAUTIONS REGARDING SAFETY.................................................................................. 240
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT.................................. 240
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT........................................................ 241
6.2 FRONT EQUIPMENT QUICK COUPLING DEVICES........................................................................... 242
6.2.1 MANUAL QUICK COUPLING .................................................................................................. 242
6.2.2 HYDRAULIC QUICK COUPLING FOR STANDARD BUCKET ............................................... 243
6.2.3 HYDRAULIC QUICK COUPLING FOR 4in1 BUCKET AND OPTIONAL EQUIPMENT
WITH UNIDIRECTIONAL OIL FLOW ...................................................................................... 243
6.3 4in1 BUCKET........................................................................................................................................ 244
6.3.1 DESCRIPTION AND CONTROLS .......................................................................................... 244
6.3.2 SAFETY DEVICES................................................................................................................... 244
6.3.3 INSTALLING THE 4in1 BUCKET ............................................................................................ 245
6.3.4 USING THE 4in1 BUCKET ...................................................................................................... 246
6.3.5 MAINTENANCE ....................................................................................................................... 246
6.4 PALLET FORKS ................................................................................................................................... 247
6.4.1 DESCRIPTION......................................................................................................................... 247
6.4.2 SAFETY DEVICES................................................................................................................... 248
6.4.3 USING THE FORKS ................................................................................................................ 248
6.4.3.1 PREPARING THE PALLET FORKS FOR USE ..................................................... 249
6.4.3.2 OVERTURNING THE FORKS ............................................................................... 249
6.4.4 REMOVING THE FORKS ........................................................................................................ 250
6.4.5 INSTALLING THE FORKS....................................................................................................... 250
6.4.6 MAINTENANCE ....................................................................................................................... 250
6.5 BACKHOE TELESCOPIC ARM............................................................................................................ 251
6.5.1 DESCRIPTION AND CONTROL.............................................................................................. 251
6.5.2 SAFETY DEVICES................................................................................................................... 252
6.5.3 USING THE TELESCOPIC ARM ............................................................................................. 252
6.5.4 MAINTENANCE ....................................................................................................................... 253
6.5.4.1 ADJUSTING THE GUIDE SLACK........................................................................... 253
6.6 CONFIGURATION FOR THE INSTALLATION OF THE DEMOLITION HAMMER ............................. 255
6.6.1 DESCRIPTION AND CONTROL.............................................................................................. 255
6.6.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED ............................. 256
6.6.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER............................................... 260
6.6.3.1 INSTALLING THE HAMMER.................................................................................. 260
6.6.3.2 REMOVING THE HAMMER.................................................................................... 262
6.6.4 USING THE HAMMER............................................................................................................. 262
6.6.5 MAINTENANCE ....................................................................................................................... 262
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6.7 APPLICATION OF THE OFFSET DEVICE........................................................................................... 263
6.7.1 DESCRIPTION AND CONTROL.............................................................................................. 263
6.7.2 MAINTENANCE........................................................................................................................ 264
6.8 CONFIGURATION FOR THE USE OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW265
6.8.1 DESCRIPTION AND CONTROL.............................................................................................. 265
6.8.2 INSTALLING AND CONNECTING THE EQUIPMENT ........................................................... 266
6.8.3 MAINTENANCE........................................................................................................................ 266
6.9 CONFIGURATION FOR THE USE OF THE CLAMSHELL BUCKET.................................................. 267
6.9.1 DESCRIPTION AND CONTROL.............................................................................................. 267
6.9.2 INSTALLING THE CLAMSHELL BUCKET............................................................................... 268
6.9.3 USING THE CLAMSHELL BUCKET........................................................................................ 269
6.9.4 MAINTENANCE........................................................................................................................ 269
6.10 CONFIGURATION FOR THE USE OF THE HAND HYDRAULIC HAMMER....................................... 270
6.10.1 DESCRIPTION AND CONTROL.............................................................................................. 270
6.10.2 INSTALLING AND REMOVING THE HAND HAMMER ........................................................... 271
6.10.2.1 CONNECTING THE HAND HAMMER.................................................................... 271
6.10.2.2 REMOVING THE CONNECTIONS ........................................................................ 272
6.10.3 USING THE HAMMER ............................................................................................................. 272
6.10.4 MAINTENANCE........................................................................................................................ 272
6.11 LOAD STABILIZER SYSTEM (LSS) (Optional) .................................................................................. 273
6.11.1 LOAD STABILIZER SYSTEM (LSS) ACCUMULATOR ........................................................... 273
6.12 REAR EQUIPMENT MECHANICAL QUICK COUPLING DEVICE ...................................................... 274
6.12.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE ...................................................... 275
6.12.2 MAINTENANCE........................................................................................................................ 276
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