Académique Documents
Professionnel Documents
Culture Documents
SK1020-5NA
SK1020-5N
SKID STEER LOADER
SERIAL NUMBERS
SK1020-5NA A60001 and UP
SK1020-5N A70001
This material is proprietary to Komatsu Utility Division and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu Utility Division.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM013900
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEBM4D9801
SAFETY MANUAL
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the
Komatsu America Corp. Extranet Literature Ordering System.
If the Extranet Literature Ordering System is not available at the distributor location, then the following
Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown
on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax
orders.
pubinfok.fm 8/26/04
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPANY NAME
SHIP TO PURCHASE ORDER NO.
ATTN.
COUNTRY
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND
MACHINE SERIAL NUMBER MUST BE SHOWN.
QTY. PUBLICATION FORM NO. PARTS BOOK PUBLICATION MODEL NUMBER SERIAL NUMBER
P-Paper DESCRIPTION
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M-Microfiche
FOREWORD
This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It
will help the operator and maintenance personnel achieve peak performance through effective, economical and
safe machine operation and maintenance.
Keep this manual handy and have all personnel read it periodically. If this manual is lost, damaged or becomes
dirty and cannot be read, request a replacement manual from your local distributor.
If you sell the machine, be sure to give this manual to the new owner.
Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this
manual. Consult your local distributor or for the latest available information on your machine or for questions re-
garding information in this manual.
This manual may contain attachments and optional equipment that are not available in your area. Consult your lo-
cal distributor or for those items that you may require.
Improper operation and maintenance of this machine can be hazardous and could result in serious injury
or death. Operators and maintenance personnel must read this manual thoroughly before operating or
maintaining this machine. This manual should be kept near or with the machine for reference and periodi-
cally reviewed by all personnel who operate it.
Some actions involved in operation and maintenance can cause a serious accident, if they are not per-
formed in the manner described in this manual. The procedures and precautions given in this manual
apply only to the intended uses of this machine. If you use your machine for any unintended uses that are
not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or
others engage in prohibited uses or actions as described in this manual.
KOMATSU delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety features and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable stan-
dards and regulations of your country, consult your local distributor or KOMATSU before operating the
machine.
The safety description is given in SAFETY INFORMATION and in the SAFETY section 1.
SAFETY INFORMATION
Most accidents are caused by failure to follow fundamental safety rules for the operation and maintenance of the
machine. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the
machine before performing maintenance and machine operations.
To identify safety messages in this manual and on machine product graphics, the following signal words are used:
Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury. This signal word is to be limited to the most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or se-
rious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
erate injury. It may also be used to alert against unsafe practices.
Remark
This word is used for precautions that must be taken to avoid actions, which could shorten the life or damage
the machine.
KOMATSU cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore the safety message in this manual and on the machine may not include all possible safety precautions. If
any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that
you and others can do such procedures and actions safely and without damaging the machine or causing injury. If
you are unsure about the safety of some procedures, contact your local distributor.
APPROVED
★ LOADING, SCRAPING OR GRADING OPERATIONS.
★ EXCAVATING.
Installation of optional equipment can also be used in the following applications, use only KOMATSU approved
equipment.
NON APPROVED
This paragraph describes some of the improper or unauthorized uses of the machine; since it is impossible to pre-
dict all the possible improper uses, if the machine happens to be used for any particular application other than
those approved above, it is important to contact your distributor before carrying out the work operations.
★ LIFTING, MOVING OR TRANSPORTING OTHER MACHINES WITH THE FRONT END LOADER OR BACK-
HOE UNIT.
PRODUCT INFORMATION
Listed are features and machine identification locations. Komatsu skid steer loader and main components are iden-
tified by serial numbers stamped on identification plates or decals attached to the machine or component.
MAIN FEATURES
★ Simple and easy operation.
★ Hydrostatic transmission obtained through a double variable displacement pump and axial piston motors
operating epicyclic reduction gears.
★ Main equipment and travel control through servo levers ensuring also combined movements that can be mod-
ulated proportionally and continually.
★ Foot accelerator.
★ Lever accelerator.
BREAK IN PERIOD
Every new machine is properly adjusted and tested before delivery. A new machine must be operated carefully for
the first 100 hours to ensure proper run-in time for the various components. It the machine is subjected to exces-
sive or severe work loads at the beginning of it’s operation, it’s functions will be greatly reduced or damaged. Every
new machine must be used carefully, paying special attention to the following indications:
★ After start up, let the engine idle at a low RPM for 5 minutes, to warm it up the machine gradually before begin-
ning actual operation.
★ Operate the machine with limited loads. Avoid abrupt starts, accelerations, sudden decelerations, abrupt rever-
sals or sudden stops.
★ After the first 50 hours, perform the following maintenance, in addition to normal maintenance performed at 50
hours:
★ After the first 250 hours, perform the following maintenance, in addition to normal maintenance performed at
250 hours perform:
PRODUCT IDENTIFICATION
The serial numbers and model numbers on the components are
the only numbers that your distributor will need when requiring
assistance or ordering replacement parts. It is a good idea to
record this information in this manual on page 0-9 (Serial Number
and Distributor Information). All views indicated below are viewed
from the operators position.
Machine #
Engine #
Travel reduction
gear #
Cab #
Excavator
(if installed)
Distributor:
Address:
Phone #
Contacts:
NOTES:
CONTENTS
INTRODUCTION
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
APPROVED AND NON APPROVED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
NON APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
PRODUCT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
MAIN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
SYNTHETIC BIODEGRADABLE OIL TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
MACHINE IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
ENGINE SERIAL NUMBER AND EMISSION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
TRAVEL REDUCTION GEAR SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
CAB SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
EXCAVATOR IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
MODEL: SK1020-5N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
SAFETY
MAINTENANCE
SPECIFICATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
STANDARD MACHINE OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . 4-4
TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
OPTIONAL ATTACHMENTS
This safety section also contains precautions for optional equipment and attachments.
SK1020-5N, SK1020-5NA
SAFETY
★ If the decals are damaged they must be replaced before operating the machine.
★ When a component provided with a safety decal is replaced, make sure the decal is also applied to the
replacement component.
★ The machine may be provided with other decals, in addition to those shown below, which must be followed for
safe operation.
A. Park machine on level ground, lower lift arm to the ground, and remove any work tools.
B. Stop engine and get out of the machine.
C. Remove retaining pin secured with a split pin and lower safety bar onto cylinder.
D. Reenter cab, secure seat belt, and start engine.
E. Slowly raise arm to the maximum height.
F. Check that the safety bar is placed at the end of the cylinder leaning against the rod.
G. Slowly lower arm until safety bar stops arm movement, checking for leaning of the safety bar.
H. Stop engine and leave the machine.
I. Put retaining pin inside the lock hole of the safety bar and place the split pin from the inside of the safety
bar.
1. Make sure the coupler pins are fully engaged and levers
are in the fully loaded position.
• Remove each hitch pin from its slot and position it in the
hole indicated by the arrow.
2( NOT APPLICABLE
3# Lubrication Chart..........................................................................................................................37A-98-11961
• When replacing damaged or missing pictogram decals, be sure they are placed in the proper location.
DECALS DEFINED
The warning and danger decals applied to the machine are accompanied or represented by pictograms. The per-
sonnel charged with the operation and maintenance of the machine must know the symbols contained in the picto-
grams perfectly; the following descriptions illustrate what they look like and their respective meanings.
Carefully read the contents of the manual before using the ma-
chine or performing maintenance operations.
REFUELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F05B2627
LIFTING POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Be sure that all personnel are at least 12 m away from any point
on the machine before moving or operating the machine. Never
allow anyone to stand near the machine while in operation. Re-
member, the larger the machine the more restricted your visibility
will be.
Never use your machine for tasks it was not designed for, dam-
age to the machine or injury to the operator may result.
Think before you act, study the job carefully. Careful operator and
service personnel are the best insurance against accidents.
The operator of this machine must be alert, physically fit, and free
from the influences of alcohol, drugs or medications that might af-
fect their eyesight, hearing, or reactions.
SAFETY FEATURES
Be sure all guards and covers are in place especially after servic-
ing the machine. Have guards or covers repaired immediately if
they are damaged. See “PRECAUTIONS BEFORE STARTING
THE ENGINE” on page 1-34.
Use safety equipment such as safety locks and seat belt properly.
Never remove any safety features. Always keep them in good op-
erating condition.
Seat belt: See “SEAT BELT” on page 2-57. Improper use of safe-
ty features could result in serious bodily injury or death. Be sure
the machine has the correct equipment required by local rules
and regulations.
Avoid loose fitting clothing, jewelry and loose long hair. These
can catch on controls or in moving parts and cause serious injury.
Wear a hard hat, safety glasses, safety shoes, mask or gloves
when operating or maintaining the machine.
Always wear safety goggles, hard hat and heavy gloves, if your
job involves driving pins with a hammer or cleaning the air clean-
er element with compressed air.
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization can create a hazard.
Before making any modifications, consult your local distributor.
Komatsu will not be responsible for any injury or damage caused
by any unauthorized modifications.
If you have to go so far away that you will not be able to see the
machine, remove the ignition key.
• Clean the handles and footboards if they are dirty with oil or
grease. Carefully clean the cab floor if it is dirty with oil,
grease, mud or rubble.
• When refuelling, hold the fuel gun firmly and keep it con-
stantly in contact with the filler until you have finished, to
avoid sparks due to static electricity.
• After refueling, tighten the fuel and oil safety caps securely.
• Do not fill the tank completely, to leave room for the fuel to
expand.
PREVENTING BURNS
Wear gloves and safety goggles when checking any fluid levels:
engine oil, hydraulic oil, engine coolant, transmission fluid.
• Do not allow any other person into the area during opera-
tion.
• Do not use optional or special equipment without the authorization of Komatsu or your Komatsu Distributor.
The installation and use of unauthorized equipment may create safety problems and adversely affect the effi-
ciency and life of the machine.
• Komatsu cannot be held liable for any damage, accident, product failure resulting from the installation and use
of unauthorized equipment.
Do not use attachments that are not authorized by your distributor. Use of unauthorized attachments could create a
safety problem and adversely affect proper operation and useful life of the machine.
Any injuries, accidents, product failures resulting from use of unauthorized attachments will not be the responsibili-
ty of Komatsu.
FIRE PREVENTION
• Completely remove all wood chips, rubbish, paper and other
flammable materials that may have accumulated inside the en-
gine compartment, since they can cause fires.
• Check the fuel and hydraulic system pipes for leaks and if nec-
essary repair them. Wipe up any excess oil, fuel or other flam-
mable fluids.
• Make sure that fire extinguishers are available in the work ar-
ea.
• Keep the cab floor and the controls (pedals and levers) clean, by removing any trace of oil and grease and, as
far as the floor is concerned, remove any excess dirt (earth, stones, etc.).
• Check the safety belt and change it if it is broken or damaged. Replace any component only with approved parts
supplied by your distributor.
ROOM VENTILATION
Exhaust gases are deadly. If starting the machine inside a build-
ing, connect a suction duct to the exhaust pipe to vent fumes out-
side.
• Make sure that all the bulbs and the working lights are functioning properly. If necessary, replace any faulty bulbs
with new ones, making sure that their power is correct.
CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WIND-
SHIELD WIPER BLADES
• Remove any trace of dirt from the cab windows and clean the rear-view mirrors, to ensure perfect visibility on the
work area.
• Adjust the rear-view mirrors that may have moved, so that the operator seated in the driving position can clearly
see the area behind the machine. If any glass is damaged, replace it with new.
• Check the condition of the windshield wiper blades; the scraping edge must be smooth, with no indentations and
attached to the rubber back of the blade.
In case of doubts about the efficiency of the edge, change the blade.
The use of the speed increase button is allowed only for the
high speed transfers of the machine.
• When moving the machine, lower the arm and roll the bucket
completely; this position makes it possible to evaluate the
space required for movement more precisely and at the same
time ensures the stability of the machine.
• If the equipment control levers must be used during travel,
avoid moving them abruptly; sudden maneuvers change the
attitude of the machine and make driving difficult.
• When traveling on rough ground, keep the speed low and
avoid sudden movements of the bucket arm.
• If possible, avoid moving on obstacles. If the machine has to
travel over an obstacle, keep the equipment as close to the
ground as possible and travel at low speed. Never move on ob-
stacles that may incline the machine considerably (over 10°).
• If one of the two wheels goes over an obstacle or gets into a
hole in the ground, the machine may overturn. In these cases,
reduce the speed to a minimum and be very careful of the bal-
ance of the machine.
WORKING ON SLOPES
• Operations on slopes and on river or lake banks with damp
ground may result in the tipping over or sliding of the machine.
• On hills, banks or slopes, keep the arm lowered and the bucket
rolled and in case of emergency quickly lower it to the ground
to help the machine stop.
• When the fuel level indicator reaches the red reserve area dur-
ing work on a slope, immediately provide for refueling; due to
the inclination of the machine, the engine may suck in air and
stop suddenly, which represents a grave risk for the safety of
the operator and of the persons in front of the machine.
PREVENTING ELECTROCUTION
• Digging operations near overhead electric lines are extremely
dangerous and may also cause death due to electrocution; for
this reason, when working near overhead electrical lines, al-
ways respect the minimum safety distances prescribed by the
competent authorities and by the accident-prevention rules in
force.
• As far as underground long-distance lines are concerned, the
minimum distance depends on the covering of the ducts in
which the cables are laid.
• When it has snowed heavily, the road shoulders and any ob-
stacles are buried in the snow and are not visible, therefore
proceed with care when clearing snow.
• The earth laid near ditches is loose and can easily collapse
due to the weight or vibrations of the machine. Be extremely
careful and remember to fasten your safety belt.
• Always use ramps that are sufficiently wide and can support
the weight of the machine. The longitudinal axes of the ramps
must be parallel to each other and perpendicular to the loading
board and their distance from each other must be sufficient to
accommodate the tread of the machine.
• Make sure that the ramps are securely positioned and an-
chored to the loading board and that they are the same length.
• Make sure that the ramp surface is clean and there is no trace
of grease, oil, soil and ice; remove any dirt from the wheels of
the machine before starting to load it on the vehicle. If the
bucket is empty or no optional accessories are fitted to the ma-
chine, this end must face the rear.
• After loading the machine, block the wheels with chocks and
secure it with tie-downs or chains that prevent any shifting
(see TRANSPORTING THE MACHINE on page 2-90.).
THE ROUTE
• Define the route to be followed, taking into account the width,
height and weight of the transporting vehicle plus the machine.
Make sure that the overall dimensions of the vehicle and its
load are compatible with the roads and any tunnel, underpass,
bridge, power and telephone line, etc. along the route.
BATTERY
SAFETY PRECAUTIONS FOR WORK ON
BATTERIES
• Electrolytic batteries contain sulfuric acid which can cause
burns. It can also corrode clothing and make holes in it. If you
inadvertently splash battery acid on yourself or on someone
else, immediately wash the affected part with plenty of water.
• Before working with batteries, stop the engine and remove the
ignition key.
• Before moving the machine, make sure that all the controls are
in neutral.
• Move the machine just far enough to permit the required re-
pairs.
• Do not remove the machine in any way other than that indicat-
ed in paragraph “HOW TO MOVE THE MACHINE” on page 2-
108.
Never stand next to the tow lines when towing the machine.
The cable or chain could break causing injury. Always stay
clear of the towing equipment.
• Use cables having the same length and pull continuously, with-
out jerks.
WARNING TAGS
Before performing any maintenance operations on this machine,
position the machine on a level and firm surface.
Lock the equipment controls, remove the ignition key and tag the
steering wheel.
Alert all personnel in your area that the machine is down for
maintenance. If necessary, tag the machine around specific
points to warn others that this machine is down for maintenance.
TOOLS
• Use only the tools provided with the machine and high-quality
tools suitable for the tasks to be performed.
PERSONNEL
Only authorized and duly trained personnel can service and re-
pair the machine; additional precautions must be taken when
grinding, welding and using a sledge hammer or heavy hammers.
Do not use your fingers, since you run the risk of cutting them.
EQUIPMENT STORAGE
The normal or special equipment that must be installed on the
machine or that have been removed must be stored in safe plac-
es, preventing them from falling down. If they fall on someone,
they can cause serious bodily harm.
Never use high pressure water or flood the inside of the opera-
tor’s cab. Doing so may damage sensitive electrical components.
When pressure washing, use high pressure, hot water, and mild
grease cutting soaps.
Always grease the machine after cleaning to push any water out
of the pivot point connections.
1-46 SK1020-5N, SK1020-5NA
SAFETY
CRITICAL PARTS
Periodically some parts must be replaced for safety purposes.
Even if these parts seem to be in good condition and operating
properly they may fail at some point causing possible injury to the
operator or pedestrian. Listed are some of the systems contain-
ing these components that may fail under extended use:
• Hydraulic hoses: all the hoses that feed and return the hydrau-
lic fluid to and from the work equipment.
Spilled fuel or oil makes the ground slippery and may cause acci-
dents; clean any dirty area immediately and carefully.
Always tighten the fuel tank and the hydraulic circuit oil safety
caps securely.
Do not use fuel to clean any part of the machine that is dirty with
oil or dust.
Always top off the fuel and oil tanks in properly ventilated areas
and refrain from smoking.
When refueling, hold the fuel gun firmly and keep it constantly in
contact with the filler until you have finished, to avoid sparks due
to static electricity.
Do not fill the tank completely, to leave room for the fuel to ex-
pand.
If it is necessary to remove the cap with the engine still hot, wear
suitable clothes and protection before loosening the cap. Loosen
the cap slowly to relieve pressure gradually.
USING LAMPS
When checking the fuel, oil, coolant or battery electrolyte levels,
always use approved explosion proof lamps.
ELECTRICAL PRECAUTIONS
When repairing the electrical system, disconnect the battery to
stop the flow of electricity.
Be aware that the fuel injector harness contains high voltage and
high amperage.
ROTATING PARTS
Take particular care near rotating parts. Keep your body at a safe
distance.
INFLATING TIRES
Always bear in mind that tires can burst while being inflated,
causing serious accidents. Before servicing the tires, observe the
following precautions:
• Before inflating tires, always check the wheel rims, tire walls
and tread for cuts, broken cords, or other damage. Have a tire
expert perform checks and tire maintenance.
1. Drain the organic oil from the tank completely. Disconnect the
hydraulic lines and drain the oil from the lines and the cylin-
ders.
2. Replace the hydraulic oil filter with a new one. Reconnect the
hydraulic oil lines.
3. Fill the hydraulic oil tank with HEES type oil.
4. Start the engine and let it idle until the hydraulic oil reaches
40°C. Operate all the work equipment to fill the hydraulic cir-
cuits.
5. Stop the engine and check the hydraulic oil level. Add oil as
needed.
The loader arm support must always rest against the hydrau-
lic cylinder rod.
The loader arm support must be brought to its final position
by moving the contact surfaces slowly and continuously, in
such a way as not to damage the cylinder head surface.
The safety bars (3) located in front of the operator seated in the driving
position make it possible to lock the equipment and travel controls.
For the operation of the safety bars (See “SAFETY BARS” on page 2-
27).
The safety guard (4) locks the optional equipment control pedal in the
neutral position.
The backhoe safety locks must be used for traveling on roads and
applied by proceeding as follows:
• After rolling back the bucket completely, apply the lock (1)
between boom and arm, the connection lock (2) between boom and
sliding plate, the center pin (3) that locks the sliding plate on the
frame, raise the stabilizer supports completely and engage the rele-
vant safety chains (4).
1- Bucket 5 - Frame
2- Bucket Cylinder 6 - Loader Arm
3- Wheels 7 - Cab
4- Lifting Cylinder
1 - Safety bars
2 - Left PPC control joystick
ISO PATTERN SYSTEM
- Travel and steering
OPTIONAL PATTERN SYSTEM
- Left wheel travel and loader arm control
3 - Right PPC control joystick
ISO PATTERN SYSTEM
- Loader arm and bucket control
OPTIONAL PATTERN SYSTEM
- Right wheel travel and bucket control
4 - Auxiliary hydraulic control pedal
5 - Foot accelerator
6 - Hand accelerator
7 - Parking brake
8 - Equipment control locking lever (if installed)
9 - Dashboard
INSTRUMENTS
1 - Hour Meter
2 - Engine Coolant Temperature Indicator
3 - Fuel Level Indicator
HOUR METER
This instrument indicates the total number of operating hours on the
engine. The count is continuous and the number is increased by 1 when
the engine has run for one hour, independently of its speed. When the
engine is running, the LED (A) positioned under the instrument flashes
and counts for every second. The hour meter keeps functioning even if
the machine is not travelling or working. The reading of the hour meter
is to be considered valid for the calculation of the maintenance inter-
vals.
The green LED’s (seat and safety bar) come on only if the op-
erator has engaged all the safety locks and released the
parking brake (red LED on). The LED’s go out whenever the
safety bar is lifted (servo controls off); to reactivate the servo
controls, sit in the driving position, lower the safety bar and
press the parking brake push button (green and red LED’s
on).
IGNITION SWITCH
This is a rotary key switch with four positions marked by the following
symbols « » - }(OFF) - I - « »(START).
For further details on the use of this switch, See “STARTING THE
ENGINE” on page 2-61.
HORN
This push button is located on the left joystick grip and serves to warn
persons in the vicinity of the machine, at the beginning of work and in
case of danger, after being pushed by the operator.
AUDIBLE ALARM
This audible alarm sounds when the circuits are energized with the igni-
tion key (rotation to position «I») and is automatically disengaged when
the engine is started.
The sounding of the alarm during operation signals:
• insufficient engine oil pressure;
• overheating of the engine cooling circuit;
• malfunction of the PPC solenoid valve coil
1 - Safety bars
2 - Left PPC control joystick
Travel and steering - ISO PATTERN SYSTEM
Left wheel travel and loader arm control - OPTIONAL PATTERN
SYSTEM
3 - Right PPC control joystick
Loader arm and bucket control - ISO PATTERN SYSTEM
Right wheel travel and bucket control - OPTIONAL PATTERN
SYSTEM
Auxiliary hydraulic kit control pedal
5 - Foot accelerator
6 - Hand accelerator
7 - Parking brake
8 - Equipment control locking lever (if installed)
9 - Super Flow hydraulic system control (continuous forward) (if
installed)
10 - Speed increase control
The locking of the PPC control safety device is performed by lifting the
safety bars (1) to a vertical position.
The safety device can be released by lowering the safety bars to the hor-
izontal position and pressing the parking brake push button (warning
light off).
Before carrying out any maneuver with this joystick, the op-
erator must be seated in the work position with the seat belt
fastened; before any maneuver the operator must take all the
precautions indicated in “3.6.5 HOW TO MOVE THE MA-
CHINE”.
Before moving, make sure that the safety bars are in the hor-
izontal (unlocked) position and the parking brake is disen-
gaged.
When traveling on roads, make sure that all the safety devic-
es have been engaged.
Failure to comply with these rules may lead to serious acci-
dents.
The left PPC control joystick (2) controls the forward/reverse move-
ments and the steering of the machine as indicated in the diagram
below.
N - Neutral
A - Forward gear
B - Counter rotation to the right
C - Reverse gear
D - Counter rotation to the left
N - Neutral
A - Forward left steering
B - Forward right steering
C - Reverse left steering
D - Reverse right steering
Before carrying out any maneuver with this joystick, the op-
erator must be seated in the work position with the seat belt
fastened and the safety bars in the unlocked (horizontal) po-
sition; before any maneuver perform the operations de-
scribed in “3.13 USING THE WORK EQUIPMENT”.
When traveling on roads, always lock the equipment con-
trols (See “EQUIPMENT CONTROL LOCKING LEVER” on
page 2-39).
Before leaving the operating position, lower the equipment
to the ground and rotate the safety bars to the locked (verti-
cal) position, then stop the engine.
Failure to comply with these instructions may lead to serious
accidents.
The right PPC control joystick (3) controls the loader arm and bucket
functions of the machine as indicated in the diagram below.
The bucket should never be rolled back more than 45° with
the arm in the dump position.
The following diagrams show the basic maneuvers and the possible
combined maneuvers.
BASIC MANEUVERS
N - Neutral
A - Arm lowering
B - Bucket dumping
C - Arm lifting
D - Bucket roll back
N - Neutral
A - Arm Lower - Bucket Roll Back
B - Arm Lower - Bucket Dump
C - Arm Raise - Bucket Dump
D - Arm Raise - Bucket Roll Back
Before carrying out any maneuver with this joystick, the op-
erator must be seated in the work position with the seat belt
fastened and the safety bars in the unlocked (horizontal) po-
sition; before any maneuver the operator must take all the
precautions indicated, See “MOVING THE MACHINE (ISO
PATTERN CONTROL SYSTEM)” on page 2-64 or See “HOW
TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL
SYSTEM)” on page 2-68 and See “OPERATING THE WORK
EQUIPMENT” on page 2-96.
Before moving, make sure the safety bars are in the horizon-
tal (unlocked) position and the parking brake is disengaged.
When traveling on roads, always lock the equipment con-
trols (See “EQUIPMENT CONTROL LOCKING LEVER” on
page 2-39).
When traveling on roads, make sure that all the safety devic-
es have been engaged.
Before leaving the work position, lower the equipment to the
ground and rotate the safety bars to the locked (vertical) po-
sition, then stop the engine.
Failure to comply with these instructions may lead to serious
accidents.
The left PPC control joystick (2) serves to control the forward and
reverse movements, the steering of the machine to the right, and the
loader arm raising and lowering functions according to the movements
indicated in the diagram below.
Before carrying out any maneuver with this joystick, the op-
erator must be seated in the work position with the seat belt
fastened; before every maneuver the operator must take all
the precautions indicated See “MOVING THE MACHINE (ISO
PATTERN CONTROL SYSTEM)” on page 2-64 or See “HOW
TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL
SYSTEM)” on page 2-68 and See “OPERATING THE WORK
EQUIPMENT” on page 2-96.
Before moving, make sure that the safety bars are in the hor-
izontal (unlocked) position and the parking brake is disen-
gaged.
When traveling on roads, always lock the equipment control
(See “EQUIPMENT CONTROL LOCKING LEVER” on page 2-
39).
When traveling on roads, make sure that all the safety devic-
es have been engaged.
Before leaving the work position, lower the equipment to the
ground and lock the safety bars (vertical position), then stop
the engine.
Failure to comply with these rules may lead to serious acci-
dents.
The right PPC control joystick (3) serves to control the forward and
reverse movements, the steering of the machine to the left, the bucket
roll back and dumping function, according to the movements indicated
in the diagram below..
N - Neutral
A - Forward left steering
B - Bucket dumping
C - Reverse left steering
D - Bucket roll back
Always engage the safety guard (2) when use of the control
is not required, during travel and when parking the machine.
When connecting a hydraulic attachment, make sure the
control pedal (1) is always in the neutral or horizontal posi-
tion and covered with the safety guard.
Never set the control pedal to the maximum flow position
unless the machine is stopped, the safety bar is in the raised
position, and the operator is seated with the seat belt fas-
tened.
The pedal (1) controls the starting and stopping of the oil flow to the
attachment and has three fixed positions (left, neutral, and right).
HAND ACCELERATOR
The use of the hand accelerator is allowed only under the in-
dicated conditions; its use in other conditions may lead to
accidents.
The hand accelerator must be used during the warming up of the engine
and successively when operations with the optional equipment are to be
carried out; it can also be used for some maintenance operations.
• Idle position :
Lever pushed completely forward.
The braking action is obtained by pressing the switch (1) (LED ON);
the release is obtained by pressing the switch again (LED OFF).
When shifted to the lock position, the lever prevents the equipment con-
trols from being used. Before traveling on roads, always lock the equip-
ment controls. Rotate the lever clockwise to lock the controls and move
it counterclockwise to unlock the controls.
The Super Flow hydraulic controls can be used when the operator needs
increased oil delivery in the attachments hydraulic system. With the
“Super Flow” hydraulic system it is possible to use equipment that
requires a high-flow hydraulic line (left) and, at the same time, a stan-
dard-flow hydraulic line (right) with limited oil flow for secondary
functions (auxiliary hydraulic kit control pedal).
Before moving the machine in any way, make sure that the
stabilizer feet are completely raised.
Before traveling on roads, make sure that the safety locks of
the stabilizer feet have been applied.
Before moving the machine in any way, make sure that the
stabilizer feet are completely raised.
Before traveling on roads, make sure that the safety locks of
the stabilizer feet have been applied.
The left stabilizer is operated by means of the button (1) installed on the
left console and according to the indicated positions.
1 - Press the button forward to lower the stabilizer foot.
2 - Press the button backward to raise the stabilizer foot.
OPTIONAL ELECTRICAL CONNECTIONS
The right three-button joystick is used when the operator needs to con-
nect electro-hydraulic equipment with several functions.
Each push button corresponds to an electric line activated by a pulse
control: press the push button to activate the electric contact; release the
push button to deactivate the contact.
This feature is only available with the Super Flow Auxiliary Hydraulics.
STANDARD VERSION
6 Red 10 Power supply for joystick switches, floating device, pattern shifting
8 Red 10 Power supply for control panel, safety unit, solenoid valve stop, con-
trol bar sensor, seat sensor, brake switch
10 Brown 7.5 Fuel pump, safety relay (against repeated starting), alternator
6 Red 10 Power supply for joystick switches, floating device, pattern shifting
8 Red 10 Power supply for control panel, safety unit, solenoid valve stop, control
bar sensor, seat sensor, brake switch
9 Brown 7.5 Back-up alarm, power supply for High-flow 3-way eqipment hydraulic
system, stabilizers, safety valves
10 Brown 7.5 Fuel pump, safety relay (against repeated starting), alternator
MAIN FUSE
The main fuse (1) is positioned near the battery and can be reached by
tilting the cab (see TILTING THE CAB on page 2-54.).
POSITION DESCRIPTION
Other relays are contained inside the base installed on panel (B) behind
the seat and can be reached by removing panel (B).
POSITION DESCRIPTION
3 Safety Unit
POSITION DESCRIPTION
4 Relay board:
A - Stop lights
B - 1 way
C - 3 way
D - Momentary high-low
E - 2 way
F - Blinking
G - Detent high-flow
POSITION DESCRIPTION
5 Stoplight relay
ENGINE HOOD
Make sure that the safety retainer (4) is engaged every time
you open the hood.
The rear panel can be opened only after opening the engine
hood.
When inspecting or carrying out a maintenance operation in-
side the rear panel, always engage the panel in the safety re-
tainer to keep it open.
To reach the release lever (2) for the rear panel (1), raise the engine
hood (See “ENGINE HOOD” on page 2-51).
To open the rear cover (1), lift the lever (2) positioned on the inner left
side of the machine, at the same time rotate the cover to the maximum
opening position and hold it open with retainer (3), by proceeding as
follows:
1. Lift retainer (3) and rotate it clockwise until it rests against the rear
cover (1).
2. Release retainer (3) and make sure that it has been engaged correctly.
To close the rear cover (1), release retainer (3), rotate it counter clock-
wise and make it rest against the rear cover (1).
Tilt the cab only with the machine parked on a firm and level
surface and with the loader arm lowered to the ground com-
plete with bucket or any other optional equipment.
Make sure that the surface on which the machine is parked is
not slippery.
Before tilting the cab, make sure that the engine hood is
open.
The cab must be raised or lowered by two people, one per
side and it is important to make sure that the handles and
hold points are not dirty with oil or grease.
After tilting the cab, always engage the safety split pin of the
cab overturning protection lock.
Do not carry out any operation on the machine if the safety
split pin of the cab overturning protection lock is not en-
gaged.
Always tighten the cab fastening screws to the torque indi-
cated in (“SPECIFIC TORQUES” on page 3-20).
When lowering the cab, be careful of the hold points and car-
ry out the operation with the help of another person.
1. Remove the safety split pin (2) of the cab overturning protection
lock (3) and put it in the appropriate seat (4).
2. Lower the rear of the cab until it touches the support surface.
3. Reassemble the fastening screws (1) and tighten them to the torque
indicated in paragraph (See “SPECIFIC TORQUES” on page 3-20)
and close the engine hood (See “ENGINE HOOD” on page 2-51).
SUSPENSION SEAT
This seat is extremely comfortable, offering four adjustment options:
a - longitudinal adjustment;
b - back inclination adjustment;
c - adjustment of the suspension, aimed at dampening the inevitable
vibrations and jerks as much as possible;
d - seat cushion inclination adjustment.
The operator can choose the driving position that is most suitable for his
physique.
The longitudinal adjustment of the seat is obtained by operating the
lever (1) and making the seat slide on the guides; once the desired posi-
tion has been found, release the lever and carry out slight movements, in
order to make sure that the lock pin is engaged in its seat.
The back adjustment is achieved by operating the lever (2); operate the
lever and try to find the position that is most suitable for the operator’s
physical structure. Three different degrees of inclination are possible.
The adjustment of the suspension is carried out with the lever (3),
according to the operator’s weight. The suspension can be stiffened or
lightened according to the operator’s needs; adjust the seat suspension
by positioning the lever (3) in one of the five seats available for this pur-
pose. Shift the lever to the left to stiffen the suspension or to the right to
lighten it.
The inclination of the seat cushion is obtained by operating the lever (4)
and positioning the front part of the cushion at the same time; it is possi-
ble to select 2 different positions.
The seat belt (1) is of the type with two coupling points and adjustable
length (2); it must be well tightened and hold the operator’s hips, while
leaving the upper part of his body completely free.
EMERGENCY EXIT
The machine is provided with an emergency exit located in the rear win-
dow (1).
In case of emergency, pull the plate (2) positioned on the upper side of
the window and remove the weather strip completely.
Push the window toward the outside.
The Operation and Maintenance Manual must be handled with care and
kept aboard the machine, so it can be easily consulted at any time. Put
the manual in the technical documentation case located inside the cab
on the left side, where the ownership documents and the logbook are
usually kept.
FIRE EXTINGUISHER
Periodically make sure that the first aid kit contains the nec-
essary disinfectants, bandages, medicine, etc. and check
their condition and expiration dates. Replace as necessary.
The first aid kit must be installed by the owner of the machine and posi-
tioned inside the cab on the right side behind the right console.
Dirt, oil, and fuel in the engine compartment near its hot
parts may damage the machine and even cause fires.
Check frequently and eliminate any leakage; if leakages
occur repeatedly, contact your distributor.
Before starting the engine, check around and under the machine to ver-
ify:
1. If there are loose screws or nuts.
2. If there are oil, fuel, or coolant leaks.
3. The wear of the work equipment.
4. The fastening of the electrical connections.
5. The fastening of the engine exhaust pipe and manifold.
6. The conditions of the rims and the wear of the tires.
7. If the safety and warning plates are sufficiently clean.
8. If the ladders and the handles for access to the operator’s seat are
clean.
Any leak or abnormality must immediately be repaired and any
trace of oil or grease must be removed. Further visual checks con-
cern:
9. The condition of the seat belt.
10. The efficiency of the instruments and of the dashboard.
11. The condition of the cab windows and the efficiency of the lights,
working lights and direction indicators.
DAILY CHECKS
Do not smoke during fuel and oil topping off and do not use
open flames or non-approved lighting to check the fuel and
oil levels, to not cause fires. If fuel, oil, or lubricants are
spilled while filling the tanks, clean the dirty areas immedi-
ately.
Before starting any operation, check the engine coolant, engine oil, and
hydraulic circuit oil levels. At the end of work, refuel to avoid the for-
mation of condensation, always checking the fuel level on the indicator
provided on the dashboard.
Avoid filling the tank completely, to leave room for the fuel to
expand. After filling the tank, put back the filler cap, making
sure that the bleed hole is completely open. Check the
engine oil level with the machine level and the hydraulic cir-
cuit oil level with the front bucket resting on the ground.
OPERATIONAL CHECKS
1. Pull the accelerator lever until reaching half of its stroke and turn
the ignition key to the preheating position « » for a maximum of
13 seconds in the coldest weather.
Preheating is indicated by the warning light located on the dash-
board.
2. Turn the ignition key to position « » (START) until the engine
starts or for a maximum of 15 seconds.
3. As soon as the engine starts, release the ignition key, which will
automatically return to position «I» and reduce the engine speed to
idle.
If the engine does not start on the first attempt, repeat steps
1 and 2 after waiting for at least 1 minute, to not overload the
battery.
3. To reduce the time necessary to warm up the engine, move the hand
accleerator lever now and then to the midpoint of its travel.
4. During the warming up of the engine, check the color of the
exhaust gases and verify if abnormal noises or vibrations can be
noticed; any problem must be verified and its cause must be elimi-
nated.
Before moving the machine, make sure that you are com-
pletely familiar with all control functions and all relevant
safety regulations.
The operator must be seated in the driving position with seat
belt fastened.
Before moving the machine, check the position of the rear-
view mirrors and make sure that there is no one within the
operating radius of the machine and that there are no obsta-
cles in the surrounding area.
Be extremely careful when engaging reverse and make sure
there are no people, working means, or obstacles in the way.
Avoid maneuvers or changes of direction when travelling at
full speed, since the maneuvers carried out under these con-
ditions cause abrupt machine movements.
Do not use the speed increase function when changing di-
rection or carrying out a counter-rotation.
The use of the speed increase function is allowed only for
fast transfers of the machine.
Before moving the machine, check the instruments, warm up the engine
and the hydraulic system oil, make sure that the safety device of the
controls is released (safety bars down) and the bucket is rolled back; the
equipment control joystick must be in neutral position.
Release the parking brake.
To turn to the LEFT, operate the travel joystick as indicated in the dia-
gram. To move FORWARD, push the joystick to the left with 45° incli-
nation. To move BACKWARD, pull the joystick to the right with 45°
inclination.
To turn to the RIGHT, operate the travel joystick as indicated in the dia-
gram. To move FORWARD, push the joystick to the right with 45°
inclination. To move BACKWARD, pull the joystick to the left with 45°
inclination.
To turn to the LEFT, shift the travel joystick to the left with an angle of
90° with respect to the longitudinal axis.
To turn to the RIGHT, shift the travel joystick to the right with an angle
of 90° with respect to the longitudinal axis.
Before moving the machine, make sure that you know the
control functions and all the relevant safety regulations per-
fectly.
The operator must be seated in the driving position with seat
belt fastened and the safety bars lowered.
Before moving the machine, check the position of the rear-
view mirrors and make sure that there is no one within the
operating radius of the machine and that there are no obsta-
cles in the surrounding area.
Be extremely careful when engaging reverse and make sure
that there are no people, working means, or obstacles in the
way.
Avoid maneuvers or changes of direction when travelling at
full speed, since the maneuvers carried out under these con-
ditions cause abrupt machine movements.
Do not use the speed increase function when changing di-
rection or carrying out a counter-rotation.
The use of the speed increase function is allowed only for
fast transfers of the machine.
Before moving the machine, check the instruments, warm up the engine
and the hydraulic system oil, make sure that the safety device of the
controls is released (safety bars down) and the bucket is rolled back; the
equipment control joysticks must be in neutral position.
Release the parking brake.
1. Pull the hand accelerator lever and set the engine at the desired
travel speed.
To turn to the LEFT, shift the left joystick to the NEUTRAL position
(N): the machine will turn to the LEFT.
To turn to the RIGHT, shift the right joystick to the NEUTRAL position
(N): the machine will turn to the RIGHT.
To turn to the LEFT, pull the left joystick backward and push the right
joystick forward.
To turn to the RIGHT, pull the right joystick backward and push the
left joystick forward.
The travel control joysticks (1) and (2) are positioned on the operator's
left and right side, respectively, and control the forward and reverse
travel of the machine according to the movements shown in the dia-
gram.
N - Neutral
A - Forward
B - Reverse
The right PPC control joystick (2) is used to control the right wheels
and also to control the auxiliary hydraulic circuit according to the
movements indicated in the following diagram:
N -Neutral
A -Right wheel forward travel
B -Right wheel reverse travel
C -Oil delivery from the male coupling of the auxiliary hydrau-
lic circuit
D -Oil delivery from the female coupling of the auxiliary
hydraulic circuit
For details on the use of the auxiliary hydraulic control, see "1.1.3
AUXILIARY HYDRAULIC CONTROL JOYSTICK"
NOTE
The horn (3) is positioned on the grip of the left joystick (1) and
must be used to warn all the people in the vicinity before starting
work and in case of danger.
All movements can be stopped by rotating the safety bars to the
vertical (locked) position. (See "SAFETY BARS").
The control pedals (1) and (2) are positioned on the floorboard in front
of the operator seat and control the movements of the loader arm and
the bucket.
N - Neutral
A - Loader arm raise
B - Loader arm lower
N - Neutral
A - Bucket roll back
B - Bucket dumping
The control joystick (1) is positioned on the operator's right and controls
the movement of the right wheels and the auxiliary hydraulic circuit,
according to the movements indicated on the plate (2) and in the follow-
ing diagram:
N - Neutral
A - Right wheel forward travel
B - Right wheel reverse travel
C - Oil delivery from the male coupling (3) of the auxiliary
hydraulic circuit
D - Oil delivery from the female coupling (4) of the auxiliary
hydraulic circuit
Before moving the machine, make sure that you are com-
pletely familiar with the control functions and all relevant
safety regulations.
The operator must be seated in the work position with seat
belt fastened and the safety bars in the unlocked (horizontal)
position.
Before moving the machine, check the position of the rear-
view mirrors (if installed) and make sure there is no one with-
in the operating radius of the machine and that there are no
obstacles in the surrounding area.
Be extremely careful when shifting into reverse and make
sure that there are no persons, other equipment, or obsta-
cles in the way.
Avoid any travel maneuver or change of direction with the
accelerator at maximum speed, since maneuvers carried out
under these conditions may cause dangerous machine
movements.
Do not use the speed increase function when changing di-
rection or carrying out a counter-rotation. The speed in-
crease function must be used only for traveling at high
speed.
Check the instruments and warm up the engine and the hydraulic sys-
tem oil before moving the machine. Make sure that the safety bars are
lowered to the horizontal (unlocked) position and that the bucket is
rolled back; the equipment control pedals must be in neutral position. At
this point, release the parking brake.
To turn to the LEFT, shift the left joystick to the NEUTRAL position
(N) and the machine will turn to the LEFT.
.
HOW TO PERFORM A COUNTER-ROTATION
1. Park the machine with the bucket directed downwards and resting
against an obstacle. If this is not possible due to the absence of nat-
ural obstacles, rotate the bucket to the dump position and thrust the
teeth into the ground.
2. Lock the equipment and travel hydraulic controls by rotating the
safety bars to the lock (vertical) position (see SAFETY BARS on
page 2-27.).
3. Engage the safety guard to lock the optional equipment control
pedal.
4. Apply the parking brake.
5. Stop the engine following the procedure indicated, (see
STOPPING THE ENGINE on page 2-89.).
6. Remove the ignition key.
7. Leave the cab using the handles and footboards.
8. Put wedges under the wheels.
9. Refuel taking the necessary precautions.
1. Check the overall dimensions; the height, width and weight of the
means of transport - machine included. It must be compatible with
the road and any tunnel, subway, bridge, electric or telephone line
that may be found on the way.
2. Observe all regulations regarding signals, speed limits, road traffic,
permits, etc.
Always use the four attaching points provided for the lifting
of the machine.
5. Lift slowly until the ropes are tensioned and make sure that the
machine is hooked correctly before lifting it off the ground.
COOLANT
3. To prevent the fluid from freezing, add distilled water in the morn-
ing, before starting work.
OTHER PRECAUTIONS
1. Before using the machine in normal operating conditions, carry out
some slow movements either forward or in reverse, and operate all
the work equipment cylinders slowly more than once. These opera-
tions serve to warm up and decrease the viscosity of the oil in the
hydraulic circuit and the transmission.
PRECAUTIONS TO BE TAKEN AT THE END
OF WORK
1. Completely remove mud and water from the machine body. Park
the machine on firm ground; if the machine must be parked near
banks or ditches, park it on wooden boards to distribute the weight
of the machine over a larger area.
2. Be careful of water drops forming on the hydraulic cylinder rods:
these drops must be completely removed, since if they freeze the
cylinder seals may be damaged. After removing the water drops,
protect the rods with oil.
3. Drain any condensate that may have formed in the fuel tank, to pre-
vent the water from freezing overnight.
4. Since the battery capacity may decrease considerably at low tem-
peratures, after work cover the battery or remove it and store it at a
suitable temperature.
If the machine should suddenly stop with the work equipment raised
due to a mechanical or hydraulic failure, the operator must lower the
equipment to the ground before leaving the machine to locate the trou-
ble. Make sure that the safety bars are lowered (open hydraulic circuit),
turn the ignition key to position «I» and lower the bucket to the ground
by shifting the equipment control joystick; only limited movements are
possible.
3. Reverse the motion of the machine and dump the bucket into the
truck.
Start loading the truck from the cab side and, if the material
is sufficiently mixed, dump from the maximum height to
increase the compaction of the material and its distribution
on the loading platform.
Travel uphill with the bucket directed forward; the same rule
must be followed when loading. Travel downhill in reverse
with the loader directed forward and bucket lowered . Move,
changing direction very slowly, with the bucket as low as
possible. Avoid any transverse position with respect to the
slope direction. Sudden movements of the bucket and dan-
gerous positions may cause the machine to overturn and
lead to serious accidents or even death
DIGGING METHOD
CORRECT
INCORRECT
• Stop the machine on a firm and level surface and lower the
bucket or attachment to the ground.
• Before leaving the machine, stop the engine, release the
residual hydraulic pressures by operating the equipment
control joystick more than once in all directions and raise
the safety bars to the locked position.
• Clean the upper and lower mounting areas of the bucket or
attachment of all dirt and debris before mounting or releas-
ing it to or from the quick coupler.
• Before starting work, make sure the quick coupler locking
pins are completely engaged in, and protruding from, the
retaining tabs (slots) provided on the bucket or attachment
and that the coupler levers are pushed down to a horizon-
tal (locking) position.
• After locking the equipment and before starting work,
make sure that the locking pins are correctly engaged and
the length of the protruding portion of the pins is in com-
pliance with the prescribed safety values (see CHECKING
THE POSITION OF THE LOCKING PINS on page 2-104.).
Keep the levers lubricated and free of dirt and debris. Lubri-
cate the coupling pins and keep the area around the pins
free of dirt and debris.
Do not use your fingers to align the holes, since your fingers
may be injured or cut in the event of the loader bucket or
attachment suddenly moving.
AVOID INJURY.
Perform all operations with the bucket or attachment at
ground level.
1. Lower the arm completely and rest the bucket on the ground in a
horizontal position.
2. Stop the engine, release any residual hydraulic pressures, raise the
safety bars to the locked position and leave the operator’s seat.
3. Pull both lock levers (1) completely upward to a vertical position to
disengage coupling pins (2).
4. Return to the operator’s seat, fasten the seat belt, lower the safety
bar, start the engine and release the brake.
5. Rotate the coupler (3) forward allowing the bucket or attachment
retaining lip (4) to slide off the top edge of the coupler.
Do not use your fingers to align the holes, since they may
become stuck or even cut in case of sudden or uncontrolled
movements.
1. Make sure that levers (1) are in a vertical position and that coupling
pins (2) are completely retracted.
2. Incline the top of coupler (3) forward and slowly approach the
bucket (4) or attachment until the top edge of the coupler is com-
pletely under the top flange of the bucket (4) or attachment. Make
sure you center the coupler with the bucket or attachment.
3. Tilt the coupler backward until the cutting edge of the bucket or
attachment is slightly off the ground.
3. If the length (1) does not appear within the specified range, adjust it
by proceeding as indicated in “ADJUSTING THE LOCKING
PINS” on page 2-105.
Start the engine and move the machine for a short distance once a
month, so a new oil film covers all the moving parts and the surfaces of
the components. Provide also for charging the battery.
AFTER THE PERIOD OF INACTIVITY
When using the machine after a long period of inactivity, proceed as fol-
lows:
1. Remove the seals from the exhaust pipe and the fuel tank.
2. Check all the fluid levels: engine oil, coolant, fuel, hydraulic circuit
oil.
3. Make sure that the battery charge is sufficient and install the bat-
tery.
4. Disconnect the engine stop solenoid.
5. Turn the ignition key directly to the start position and keep it there
until the engine oil pressure warning light goes out. This operation
serves to start the circulation of the lubricating oil and to carry out a
first lubrication cycle.
6. Reconnect the stop solenoid valve and start the engine.
7. Run the engine at idle for about 20 minutes.
8. While the engine is warming up, remove the protection grease from
the hydraulic cylinder rods.
9. Before moving the machine, make sure that the instruments, the
warning lights, working lights work properly.
10. Warm up the hydraulic cylinders, by slowly moving all the work
equipment as soon as possible.
When moving the machine, use a wire rope suitable for the
weight of the machine to be removed.
If the machine gets stuck in mud and cannot get out using only its
motive power, or in case of breakdown, use a wire rope as shown in the
figure at right.
When the engine has started, remove the cables in reverse order of the
connection process.
1. Disconnect the negative cable (-) from the engine block of the
engine that has been started and then from the battery B.
2. Disconnect the positive cable (+) first from the battery used for the
starting and then from the depleted battery A.
Lights come on intermittently with en- • Faulty fan belt tension ✩ Adjust fan tension, see EVERY
gine running
250 HOURS.
Starter pinion engages and then dis- • Battery charge insufficient ✩ Charge battery
engages
Starter makes engine turn slowly • Battery charge insufficient ✩ Charge battery
• Faulty starter ★ Change
Starter disengages before engine has • Faulty cables ★ Check and repair
started • Battery charge insufficient ✩ Charge battery
Steam comes out of radiator breather • Fluid level low, fluid leakage. ✩ Top off, repair.
pipe • Fan belt slackened. ✩ Check and adjust belt tension.
• Mud or limestone accumulated in ✩ Change fluid and clean cooling
cooling system. system.
Engine coolant temperature indicator • Radiator fins damaged or closed. ✩ Repair or clean.
reaches overheating (red) range:
• Faulty thermostat. ★ Change.
• Radiator cap loose or broken. ✩ Tighten cap or change unit.
(Working at considerable altitude)
Exhaust gases white or light blue • Too much oil in oil pan. ✩ Correct oil level.
• Unsuitable fuel. ✩ Change with suitable fuel.
Abnormal noises, during combustion • Fuel with low cetane rating. ✩ Change to fuel compliant with
or in mechanical parts standards.
• Overheating. ✩ See defects of temperature indica-
tor.
• Muffler insides damaged. ★ Change.
• Excessive valve clearance. ★ Adjust valve clearance.
Traction force in the two travel • Endothermic engine does not reach max. speed. ★ Change diesel oil filter and
directions is insufficient check injection pump.
• Auxiliary fuel pump (gear pump) faulty. ★ Repair or change.
• Max. pressure valve setting incorrect. ★ Set.
• Connection to servo control faulty lever angle ★ Restore connection shift lever
incorrect. to correct position.
• Pressure relief valve setting incorrect. ★ Set.
• Excessive oil temperature. ✩ Check oil level and clean ex-
changer.
• Travel motor faulty.
★ Repair or change.
Traction force is insufficient in • Endothermic engine strongly overloaded. ✩ Reduce loads due to lifting.
one direction only • Incorrect setting of the max. pressure valve rele- ★ Set valve.
vant to that direction.
Machine decelerates intermittently • Mechanical connection with servo ★ Check if rotation is smooth.
control lever too hard.
Machine accelerates slowly. • Engine power drop. ★ Check clogging of diesel oil filter,
injection pump and valves.
• Pressure relief valve setting incor- ★ Set to rated value.
rect.
Oils, filters, coolant, and the batteries are considered special waste and must be collected and disposed of
according to the regulations in force. Combustible material of some components may become extremely
dangerous if it burns. For this reason, avoid any contact of burnt material with your skin or eyes and do
not inhale fumes.
ITEM SPECIFICATIONS
SAE 5W-30
SAE 10W
Engine oil 10 l 10 l
SAE 30
pan (2.64 gal) (2.64 ga)
API CD
Oil
SAE 40
SAE 10W-30
Hydraulic
See
system with 50 l 32 l
page 3-
biodegrad- (13.2 gal) (8.4 gal)
12
able oil
ASTM D975
Diesel No. 1 72l
Fuel tank -
fuel (19.0 gal)
ASTM D975 No. 2
Perma-
Engine cool- 15 l
nent -
ing system (3.9 gal)
Coolant
GREASE
Note 1:
The recommended lubricating grease is No.2 multi purpose lithium grease with 3% molybdenum disulfide (Lithio EP +
MoS2).
★ When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE10W,
SAE5W-30 and SAE10W-30, even though an atmospheric temperature goes up 10°C more during the day time.
★ Use engine oil with CD classifications; if oil with CC classification is used, reduce the engine oil change interval by one
half.
★ Use genuine Komatsu oil which has been specifically formulated and approved for use in the engine, hydraulic work
equipment, in the reduction gears, and in the transmission.
First filling quantity: total quantity of oil, including the oil for the components and pipes.
Oil change quantity: quantity of oil necessary to fill the system or unit during the normal inspection and maintenance opera-
tions.
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
API: American Petroleum Institute
NLGI: National Lubricant Grease Institute
Antifreeze Coolant
Transmission Oil
Engine Oil [Ethylene Glycol
No. Supplier GM Dexron® II C4 Grease LI, EP, MoS2
API CD, CE or CF-4 Base]
Allison C4
Permanent Type
1 KOMATSU Premium multi grade Komatsu PM704 Komatsu Super Grease
Engine Oils PM701 (1902) Dexron® III NLGI 2
–
SAE 10W/30 PM706
SAE 15W/40 ASTM D128
2 AMOCO Amoco 300 Dexron II ATF Molylith grease 2 Ready Antifreeze
SAE 15W/40
3 ARCO Arcofleet S3 plus ATF Dexron II Litholine HEP 2 Sincol-Blu (-40°C)
SAE 15W/40 Arco EP moly D
Hy-Vis HD extra S3
plus SAE 15W/40
4 BP Vanellus C3 Autran MBX Grease LTX2-M Sigil Fluid (-40°C)
SAE 15W/40
Vanellus C3 Extra
SAE 15W/40
5 CALTEX RPM Delo 500 ATF-HD Molytex EP2 AF engine coolant
RPM Delo 600 CX engine coolant
RPM Delo SPH
6 CASTROL Turbomax RX super TQ - Dexron II Spheerol LMM Antifreeze (pure)
7 CHEVRON Delo 400 Supreme Automatic Moly grease Flurant
Delo 500 Transmission Fluid
8 CITGO – D-21571 – –
9 CONOCO *Fleet motor oil D21718 Fleet Heavy Duty
–
SAE 15W/40 D21570
10 EXXON Essolube TD ATF Dexron II D MP Grease All-season coolant
(ESSO) SAE 15W/40 D-21849 (East Canada) Moly
Heavy Truck Diesel D-21848 (West Canada)
Motor Oil SAE 15W/
40
11 GULF Super duty Gulfcrown EP2 Antifeeze and coolant
SAE 15W/40 Gulfcrown EP special
–
Super duty plus
SAE 15W/40
12 MOBIL Delvac 1300 Super ATF 220 Mobilgrease sp.I ó
SAE 15W/40
Delvac 1200 Super –
SAE 15W/40
Delvac 1300 Super
SAE 10W/30
13 PENNZOIL Supreme duty fleet Pennzoil ATF Multi-purpose white grease Antifreeze and sum-
SAE 14W/40 705 mer coolant
707L White-bearing grease
14 SHELL Rimula Super Donag TG (Dexron II) Alvania EP grease Shellzone all season
SAE 15W/40 MP MOS (Can.) antifreeze
Myrina X Retinax AM (Corea)
SAE 15W/40
Rotella T
SAE 10W/30
15 SUN - - Sunoco ultra prestige 2EP Sunoco antifreeze and
Sun prestige 742 summer coolant
AGIP –
ARAL –
AVIA –
BP –
CONDAT CONDAT D 46 K
ELF –
ESSO –
FINA BIOYIDRAN SE 46
FUCHS –
KENDALL –
KUWAIT PETROLEUM K8 –
MOBIL (USA) –
PAKELO –
TAMOIL –
TEXACO –
TOTAL HYDROBIO 46
VAVOLINE –
It Is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when
the temperature increases insoluble compounds are generated, which are deposited on the filters and clog
them (the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil). The syn-
thetic biodegradable oil can be used only in the hydraulic system; it cannot be used for the endothermic
motor, the transmissions, the braking system, etc. Before introducing the synthetic biodegradable oil in
the hydraulic system, empty the system completely, disconnecting the cylinders and all the parts that may
contain ordinary oil, and replace the drain filter with a new one. Start the engine and let it idle without using
the work equipment, wait until the oil reaches a temperature of at least 40°C, then start moving the equip-
ment, so that all the parts of the system are filled with oil. Stop the engine and check the oil level,
(see HYDRAULIC SYSTEM OIL LEVEL on page 3-32.)
For the lubrication procedures for the single points, see MAINTENANCE PLAN on page 3-21..
The type of lubricant to be used is indicated in the lubricant table (See “FUEL, COOLANT AND LUBRICANTS” on page 3-
6).
GENERAL
Check before starting Leakage from joints, grease fittings, hydraulic hoses, or fuel
lines.
Periodic check (monthly check) Leakage from joints, fittings, hydraulic hoses, or fuel lines.
Damaged hydraulic or fuel lines, cracks, wear and tear.
Periodic check (annual check) Leakage from joints, fittings, hydraulic hoses fuel lines.
Deteriorated, twisted, damaged hydraulic hoses fuel lines,
cracks, wear and tear, or in contact with other parts of the
machine.
★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual sec-
tion regarding the components connected with safety and components that must be periodically replaced. When replacing
hoses, always change o-rings, gaskets, and associated components.
★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual sec-
tion regarding the components connected with safety and components that must be periodically replaced. When replacing
hoses, always change o-rings, gaskets, and associated components.
★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual sec-
tion regarding the components connected with safety and components that must be periodically replaced. When replacing
hoses, always change o-rings, gaskets, and associated components.
16 2 24 191 ± 21 268 ± 29
18 2.5 27 262 ± 28 366 ± 36
20 2.5 30 372 ± 40 524 ± 57
22 2.5 32 511 ± 57 719 ± 80
24 3 36 644 ± 70 905 ± 98
SPECIFIC TORQUES
This torque table is not valid for bolts or nuts that contain nylon parts or spring washers.
WHEN REQUIRED
a. Coolant Change 53
The air cleaner can be reached after raising the engine hood and open-
ing the rear panel. To clean the primary element, proceed as follows:
1. Release safety locks b, moving them toward the outside and
remove the filter cover c.
2. Remove the main filtering element d.
3. Lightly tap the filter element d on the palm of your hand, in a man-
ner to remove the dust, and blow compressed air on the inner sur-
face, keeping the air jet at a distance of approximately 15 cm (5.9
in.) and taking care to prevent pressure from exceeding 4 to 5 kg/
cm² (58-73 psi).
4. Carefully clean the inside of the filter case e, taking care to prevent
foreign debris from getting into the suction duct and reassemble the
unit making sure that the ejector is positioned vertically and at the
bottom.
TIRE ROTATION
When draining the fuel tank, avoid spilling fuel, since this
may cause fires.
If some fuel is accidentally spilled, clean the dirty area imme-
diately, to prevent it from getting slippery and to avoid fires.
This operation serves to let all the impurities and the condensate flow
out of the tank.
Proceed as follows:
1. Raise the engine hood (see ENGINE HOOD on page 2-51.).
2. Open the valve (1), using the lever (2) supplied with the machine.
3. Turn the extension (2) counterclockwise, until clean fuel flows out.
4. Turn the extension (2) clockwise to stop the fuel flow.
5. Close the engine hood (see ENGINE HOOD on page 2-51.) and
put the extension (2) in the technical documentation case (See
“TECHNICAL DOCUMENTATION CASE” on page 2-58).
Check the battery charge level only with the engine stopped.
To prevent gas explosions, do not use open flames, do not
smoke, and avoid producing sparks due to short circuits.
The battery electrolyte is dangerous: in case of contact with
the eyes or the skin, wash with plenty of running water and
consult a doctor. The battery is maintenance-free.
The battery (1) can be reached after opening the engine hood
(see ENGINE HOOD on page 2-51.).
The change of color of the indicator shows the battery charge level,
according to the table positioned beside the indicator itself:
- Green: the charge is correct
- Grey: the battery needs recharging
- White: the battery must be changed
Dirt, oil, and fuel spread in the engine compartment near hot
areas may cause fires and damage the machine. Check to
see if there are frequent leaks, and perform any necessary
repairs immediately. If this occurs repeatedly, contact your
distributor.
Carry out this check with the machine parked on a level sur-
face and the equipment resting on the ground.
Do not remove the radiator cap; the coolant level must be
checked with cold engine and the coolant reservoir.
The coolant reservoir (1) can be reached by raising the engine hood
(see ENGINE HOOD on page 2-51.) and opening the rear panel
(see REAR PANEL on page 2-52.). The coolant level must fall between
the MIN. and MAX. marks.
If necessary, add coolant and, if a constant and considerable decrease in
the fluid level is noticed, check the tightness of the radiator-engine unit
and of the radiator.
To check the fuel level, use the indicator (1) positioned on the dash-
board, after turning the ignition key to position «I».
To refuel, if necessary, open the engine hood (see ENGINE HOOD on
page 2-51.).
Do not fill the tank completely, in order to leave room for the fuel to
expand.
After the machine is stopped, the engine is very hot. Let the
engine cool down before performing any check. Hot engines
may cause burns. If it is necessary to check the oil level dur-
ing or soon after work, stop the engine and wait for 15 min-
utes before checking.
The dipstick b can be reached after opening the engine hood. The check
must be performed with a cold engine and the machine located on level
ground.
The oil level can be checked on the graduated dipstick b and must be
between MIN. and MAX. marks. If the level is near the MIN. mark, top
off with oil, through filler tube c, of the same brand, suitable for the
ambient temperature, as prescribed in the lubricant chart (see FUEL,
COOLANT AND LUBRICANTS on page 3-6.).
To check the oil level in the hydraulic circuit, open the rear panel
(see REAR PANEL on page 2-52.). The oil level must be visible
through the gauge (1) positioned on the tank and must be between the
MIN. and MAX. marks. If the level is near the MIN. mark, top off
through the filling opening (2) with suitable hydraulic oil (see FUEL,
COOLANT AND LUBRICANTS on page 3-6.), after removing the
cap. Reinstall and tighten the cap after topping off.
The water separator can be reached after opening the engine hood
(see ENGINE HOOD on page 2-51.). The check must be carried out by
means of the red ring (1) installed in the filter.When the red ring floats
on the surface of the water contained in the water separator, it is neces-
sary to drain it. Provide a suitable container to catch the drained liquid.
Proceed as follows:
1. Turn the valve (2) to close the fuel flow.
2. Loosen the wing cap (3) and drain the condensate until clear diesel
fuel flows out. Reclose the wing cap (3).
3. Open the valve (2).
4. Drain the fuel tank as described in paragraph “DRAINING THE
FUEL TANK” on page 3-26.
5. Bleed the fuel supply circuit as described in paragraph “CHANG-
ING THE FUEL FILTER” on page 3-44.
6. Properly dispose of the drained liquid.
Make sure that there are no disconnected cables or signs of short cir-
cuits in the electrical system. Make sure that all the cables are well
tightened in the corresponding terminals; tighten any loose cables.
Inflate the tires standing beside the outer belt. Do not exceed
the pressures recommended in the “TECHNICAL SPECIFI-
CATIONS” on page 4-6.
Carry out this check with the machine parked on a level sur-
face and the equipment resting on the ground. Do not re-
move the radiator cap when the fluid is hot, since it may be
sprayed out violently and cause burns. Loosen the cap slow-
ly in order to release the pressure before removing it.
The radiator cap can be reached after raising the engine hood
(see ENGINE HOOD on page 2-51.). Remove the cap (1) and make
sure that the fluid level reaches the filling hole.
If the fluid level in the radiator is low and the expansion tank
is full of coolant, check the tightness of the radiator cap and
make sure that there is no air leakage from the radiator to ex-
pansion tank coupling. If this inconvenience occurs repeat-
edly, contact your distributor.
If the belt is worn, replace it and check the tension again af-
ter a few hours of operation.
Stop the machine on firm and level ground, raise the front
and rear wheels until they are not in contact with the ground
any longer and engage all the safety locks before stopping
the engine. Secure the machine in this position by applying
bearing blocks under the front part of the frame.
FRONT CHAINS
After raising the front part of the machine and securing it in this posi-
tion with safety blocks, mark a point on the outer perimeter of the front
rim and, moving the wheel, make sure that the point moves a distance
between 2 and 6 mm. This range determines the correct tension of the
chain. Repeat this operation for the opposite wheel.
REAR CHAINS
After raising the rear part of the machine and securing it in this position
with safety blocks, mark a point on the outer perimeter of the rear rim
and, moving the wheel, make sure that the point moves a distance
between 2 and 6 mm. This range determines the correct tension of the
chain. Repeat this operation for the opposite wheel.
Check the tension on the front and rear wheels and if the
slack exceeds 6 mm, contact your distributor.
If the wheel slack exceeds 6 mm, carry out the following operations:
1. Remove the wheel nuts using a 24 mm hexagon wrench.
2. Position the adjusting screw (3), included with the machine, in the
appropriate adjusting tab and tighten it to touch the hub-holding
plate (1). Use a 17 mm hexagon wrench.
3. Loosen the nuts (2) of the hub-holding plate (1), giving them a
max. of 2 full turns. Use a 22 mm hexagon wrench.
4. Tighten the screw (3), to push the hub-holding plate 1 or 2 mm.
5. Tighten at least 3 nuts (2), opposite of each other, on the hub-hold-
ing plate.
6. Install the wheel and check the wheel slack. If the wheel slack
value is not within the prescribed value range, repeat the operation
described above.
If, on the contrary, the wheel slack value is within the range, proceed as
follows:
7. Remove the wheel again.
8. Tighten all the nuts (2) of the hub-holding plate (1) to the specified
torque (see STANDARD TORQUE FOR BOLTS AND NUTS on
page 3-20.).
9. Remove the adjusting screw (3).
10. Reassemble the wheel, tightening the nuts to the specified torque
(see SPECIFIC TORQUES on page 3-20.).
Repeat this procedure for the other wheels.
Check the oil level in the chain case after the machine is back on the ground.
The radiator/hydraulic oil cooler can be cleaned after opening the rear
panel (see REAR PANEL on page 2-52.), using a compressed air jet
and, if necessary, carrying out a washing cycle with low pressure water
or steam; the specific detergents available on the market can be used,
provided that the instructions given on the package are followed and
that at the end of the operations the washed parts are rinsed and dried.
On new machines, check the wheel nut torque after the first
50 hours of operation and successively every 250 hours.
This check serves to restore the correct torque to the wheels on the hubs.
The torque must be checked with a torque wrench (1) containing the
values indicated in paragraph “SPECIFIC TORQUES” on page 3-20.
Use a 24 mm wrench.
Clean the grease nipples before applying the grease pump. After lubrication, remove any excess grease.
If the machine is used in difficult conditions, perform these maintenance operations more frequently.
These maintenance operations must be carried out with the arm completely lowered and the bucket resting on the ground. For
the lubrication, use a grease pump and the recommended grease. (see FUEL, COOLANT AND LUBRICANTS on page 3-6.).
As a general rule, consider that each cylinder is provided with two grease nipples positioned on the cou-
plings and that each pin serving as fulcrum for a movement is provided with at least one grease nipple.
Immediately after the engine has been shut off the engine oil
is very hot and may cause burns; let the engine cool down
until it reaches a temperature of 40-45°C (104-113°F) before
draining the oil.
The oil that may be spilled during the change makes the
ground slippery, therefore, use anti-slip shoes and immedi-
ately remove any trace of oil from the floor.
Oils, filters, coolants and batteries are considered special
waste and must be collected and disposed of according to
the anti-pollution regulations in force.
Drain the oil after positioning the drain hose outside the en-
gine compartment.
Change the engine oil at the same time as the engine oil filter
(see CHANGING THE ENGINE OIL FILTER on page 3-42.). This
operation must be carried out with the machine parked on firm and level
ground and the step succession is the following:
1. Detach the lower cover (1) after removing the fastening screws (2).
Use a 17 mm spanner.
2. Extract the oil drain flexible pipe (3) from the lower opening.
3. Raise the engine hood (see ENGINE HOOD on page 2-51.).
4. Remove the drain plug (4) of the drain hose (3), gathering the used
oil that flows out into a container with suitable capacity. Use a 27
mm wrench. While the oil flows out, remove the filler cap (5), so
that the oil can flow freely.
5. After the oil has completely drained from the pan, screw the drain
plug (4) back into the drain hose and pour the specified quantity of
new oil into the pan, using the dipstick (6) to make sure that the oil
reaches the MAX. level.
6. Replace the filler cap (5), start the engine, let it run for 5 minutes
and then stop it. Check the level again and top off, if necessary.
7. Close the lower cover (1).
8. Close the engine hood.
Use oil suitable for the ambient temperature (see FUEL, COOLANT
AND LUBRICANTS on page 3-6.).
After the oil change and after removing any trace of oil, put
the drain hose back inside the engine compartment.
Do not use the wrench to tighten the filter, since this may
cause damage and result in oil leaks.
Change the filter element after work and after the engine has
cooled down to 40-45°C (104-113°F). When this operation is
performed, fuel may spill; clean the spill immediately, to pre-
vent any risk of slipping or fire. Oils, filters, coolants and bat-
teries are considered special waste and must be collected
and disposed of according to the anti-pollution regulations
in force.
The fuel filter and the fuel pump can be reached by opening the engine
hood (see ENGINE HOOD on page 2-51.).
FUEL FILTER
1. Clean the outside of the filter and then unscrew the used filter (1)
with the special wrench provided and dispose of the filter properly.
2. Clean the inside of the head (2).
3. Lubricate the new filter seal and screw on until the seal contacts the
base.
4. Give the filter a further half turn by hand.
5. Bleed the fuel supply circuit.
BLEEDING THE CIRCUIT
After filling the tank, turn the ignition key to position «I» and wait for
approximately 15-20 seconds, to bleed the fuel supply circuit.
The filter is positioned on the hydraulic system drain outlet and blocks
the metal particles that come off the various components due to their
wear. The filter can be reached after opening the rear panel (see REAR
PANEL on page 2-52.).
To change it, proceed as follows:
1. Slowly loosen the filler cap (1) to release the residual pressure from
the tank and then remove the cap.
2. Unscrew the used filter (2) and discard it.
3. Clean the contact surface between the seal and the filter base (3),
lubricate the seal of the new filter and screw on until the seal con-
tacts the base.
4. Give the filter a further half turn by hand.
5. Close the rear panel.
6. Check for oil leaks after running the engine.
Do not use the wrench to tighten the filter, since this may
cause damage and result in oil leakage. If the machine con-
tains synthetic biodegradable oil type HEES, the filter must
be changed after the first 50 hours of operation.
Change the precleaner at the end of work and after the en-
gine has cooled down to 40-45°C (104-113°F). When these
operations are performed, fuel may spill; clean the dirty ar-
eas immediately, to prevent any risk of slipping or fire.
The water separator can be reached after opening the engine hood
(see ENGINE HOOD on page 2-51.).
CLEANING THE WATER SEPARATOR.
1. Close the valve (1).
2. Loosen the metal ring (2) and remove the cup (3) and the filtering
element, collect the fluid in a container of suitable capacity.
3. Clean the inside of the cup and the filter with diesel oil or oil.
4. Replace the filter and the cup (3), tighten the metal ring (2) and
open the valve (1).
After filling the tank, turn the ignition key to position «I» and wait for
approximately 15-20 seconds, to bleed the fuel supply circuit.
Stop the machine on a firm and level surface, lower the equipment to
the ground, stop the engine and release the residual pressures that may
be present in the equipment by operating the controls more than once.
Raise the engine hood (see ENGINE HOOD on page 2-51.) and open
the rear panel (see REAR PANEL on page 2-52.).
1. Slowly loosen the filler cap (1) to release the residual pressure from
the tank and remove the cap.
2. Position a container of suitable capacity under the drain plug.
This operation must be carried out on each case with the machine
parked on level ground and at operating temperature, so the oil flows
freely and can be drained easily together with the solid particles sus-
pended in it.
1. Remove the drain plug (1) and let the used oil drain completely.
Use a 19 mm hexagon wrench.
2. While the oil flows out, remove the fill plug (2). Use a 19 mm
hexagon wrench.
3. After draining the used oil, replace the plug (1) and fill with the
recommended oil through the fill hole (2) until the oil reaches the
lower edge of the hole.
4. Reinstall the plug (2).
Move the machine back and forth and check the level again with the
machine at rest. Use only the recommended type of oil (see FUEL,
COOLANT AND LUBRICANTS on page 3-6.).
Stop the machine on a firm and level surface, lower the equipment to
the ground, stop the engine and release the residual pressures from the
work equipment circuits by operating the controls more than once.
Raise the engine hood (see ENGINE HOOD on page 2-51.) and open
the rear panel (see REAR PANEL on page 2-52.).
1. Slowly loosen the filler cap (1) to release the residual pressure from
the tank and then remove the cap.
Never start the engine with empty tank, since this would cer-
tainly damage the pump.
1. Raise the engine hood (see ENGINE HOOD on page 2-51.) and
open the rear panel (see REAR PANEL on page 2-52.).
2. Loosen and remove the filler cap (1) of the radiator.
3. Open the drain cock (2) of the radiator, remove the drain plug (3)
positioned on the engine block and let the fluid flow into a suitable
size container. Use a 17 mm hexagon wrench. While the fluid flows
out, drain the coolant tank (4).
4. Close the drain cock (2) and install the plug (3) on the engine
block. Fill the radiator with new coolant (see FUEL, COOLANT
AND LUBRICANTS on page 3-6.).
Stop the machine on a firm and level surface, lower the equipment to
the ground, stop the engine and release the residual pressures from the
equipment by operating the controls more than once.
Raise the engine hood (see ENGINE HOOD on page 2-51.) and open
the rear panel (see REAR PANEL on page 2-52.).
The suction filter must be changed every two hydraulic oil changes.
1. Slowly loosen the filler cap (1) in order to release the residual pres-
sure from the tank and then remove it.
Never start the engine with empty tank, since this would cer-
tainly damage the pump.
OVERALL DIMENSIONS WITH STANDARD BUCKET L 1880 (6’2”) AND TIRES (12-16.5)
Unit: mm
OVERALL DIMENSIONS WITH NARROW BUCKET L 1730 (5’8”) AND TIRES (12-16.5)
TECHNICAL SPECIFICATIONS
TOTAL WEIGHT
Standard machine max. 3350 kg (7385 lb)
Max. with bucket L 1730 3330 kg (7341 lb)
Max. with bucket L 1880 3350 kg (7385 lb)
Max. total mass with excavator E35-2 4200 kg (9259 lb)
Max. total mass with asphalt cutter 4250 kg (9370 lb)
BUCKET CAPACITY
Standard bucket L 1880 (SAE) 0.42 cu.m. (0.55 cu.yd.)
Narrow bucket L 1730 (SAE) 0.40 cu.m. (0.52 cu.yd.)
Wide bucket L2030 (SAE) 0.45 cu.m. (0.59 cu.yd.)
ENGINE
Komatsu diesel engine model S4D98E-2NFE
Rated power (2500 rpm EEC 80/1269) 64 kW (85.8 HP)
Maximum torque (1600 rpm EEC 80/1269) 286 Nm (211 lb.ft)
ELECTRICAL SYSTEM
Alternator 12 V
Electrical output 40 A
Ground Negative
Battery 100 Ah-12 V
Starter 3.0 kW (4.02 HP)
SPEED
FORWARD REVERSE
GEARS 1 2 1 2
km/h 10 15.5 10 15.5
MPH 6.2 9.6 6.2 9.6
TIRES
SIZE MAKE INFLATION PRESSURE
12x16.5 PR10 OMEGA 4 bar (58 psi)
12x16.5 PR10 HAULER 4 bar (58 psi)
12x16.5 PR10 GOOD-YEAR 4 bar (58 psi)
2x16.5 PR10 AIR BOSS
BASIC PRECAUTIONS
The installation of optional accessories or equipment other than those
authorized by Komatsu shortens the life of the machine and may also
cause problems concerning safety. It is advisable to contact a Komatsu
Distributor before installing any accessory not indicated in this opera-
tion and maintenance manual. In case of failure to comply with this rec-
ommendation, Komatsu declines any responsibility for accidents or
damage.
Excavator
1100 ● ❑3200 Excavator
206 80
(2425) – (126.0) (2988) (21.1)
73 800
Excavator bucket – – – –
(161) (31.5)
150 206 80
Hydraulic hammer – – –
(331) (2988) (21.1)
● - Maximum outreach
❑ - Maximum digging depth
❊ - Measurement referenced to the tool diameter
▲ - Maximum tool length
Excavator
1100 ● ❑3200 Excavator
206 80
(2425) – (126.0) (2988) (21.1)
73 800
Excavator bucket – – – –
(161) (31.5)
150 206 80
Hydraulic hammer – – –
(331) (2988) (21.1)
● - Maximum outreach
❑ - Maximum digging depth
❊ - Measurement referenced to the tool diameter
▲ - Maximum tool length
Stop the machine on a firm and level surface and lower the
equipment to the ground.
Before getting off the machine, stop the engine, release the
residual pressures by moving the equipment control levers
more than once in all directions and lock the safety bars (See
“SAFETY BARS” on page 2-27).
Before starting work, make sure the quick coupler locking
pins are completely engaged in, and protruding from, the re-
taining tabs (slots) provided on the bucket or attachment and
that the coupler levers are pushed down to a horizontal
(locking) position.
Do not use your fingers to center the pins, since they may be
injured or even cut due to sudden or uncontrolled move-
ments.
The machine may be fitted for the attachment of equipment with a sepa-
rate return circuit directly into the tank.
The return system is positioned on the left side of the loader arm and the
equipment drain pipe must be connected to the union (1).
Before using the forks for any operation, the operator must
get acquainted with the increased dimensions of the ma-
chine and must also practice the use of the swinging move-
ments.
After grasping the material with the forks and before lifting
the load, swing the equipment in such a way as to lift the tips
of the forks and prevent the load from slipping.
Use the lifting, swing and travel controls slowly and smooth-
ly, to avoid jerks that may cause the load to move.
Use the maximum fork width possible.
The forks must always be resting on the plate and be se-
cured in their position with the safety pins.
The pallet forks make it possible to use the machine like a normal lift
truck and the controls for lifting and swinging the loads are the same
used to control the standard bucket. See “MACHINE CONTROLS” on
page 2-25.
The pallet forks may require being set to different widths (distance from
each other) according to the load to be handled: adjustment is made by
sliding them on the upper coupling bar; once the desired position has
been found, carry out slight movements to make sure that the upper lock
pin is engaged in its seat.
STATE OR PROVINCE:
DEPARTMENT: COUNTRY:
NAME: FAX:
BOOK DESCRIPTION
MACHINE MODEL & S/N:
PROBLEM:
CORRECTIVE ACTION:
PROPFREV.FM 100903