A tachometer reading of 2000 RPM without wheel slip on a Komatsu Utility WB97S-2 could be caused by low engine RPM affecting stall speed or a condition similar to overheating. Possible causes include:

- Low engine RPM: Check and adjust the engine governor.
- Overheating-related issues: These may involve damaged rings, a faulty pump, low oil level, or a dirty or damaged heat exchanger.

Refer to remedies listed under "Lack of power" and "Overheating" in the troubleshooting section.

This answer is automatically generated

John Kerr

March 30, 2025

Komatsu WB97S -2 Backhoe problem Rear steering ram has locked the wheels in the right direction and will not return to neutral position, front ram was leaking but now has been serviced would an air lock be the issue ? or would the solenoid coils cause this problem ?

1 comments:

Mr. Anderson

March 30, 2025

The rear steering ram on a Komatsu WB97S-2 backhoe could lock the wheels in the right direction and not return to the neutral position if the crab steering is selected while the machine is moving or not in 1st or 2nd gear. The manual states that crab steering must only be selected with the machine at rest and in 1st or 2nd gear. Ignoring this may cause steering system malfunctions, including the ram locking in one direction.

This answer is automatically generated

Summary of Contents for Komatsu Utility WB97S-2

Page 1 WEAM000704 Operation & Maintenance Manual WB97S BACKHOE-LOADER SERIAL NUMBER WB97S-2 97SF11205 and up WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintain- ing this machine.
Page 3: Foreword
1.1 FOREWORD • This manual has been carried out by Komatsu Utility in order to supply their customers with all the necessary information on the machine and the safety regulations related to it, together with the use and maintenance in- structions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time.
Page 4: Information On Safety
Komatsu Utility cannot reasonably predict every circumstance that might involve a potential hazard during the op- eration or maintenance of the machine; for this reason, the safety messages included in this manual and applied onto the machine may not include all possible safety precautions.
Page 5 INFORMATION ON SAFETY DANGER • It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu Utility can- not be held liable for any damage to persons, property or the machine, if this has been tampered with by modifying the standard setting of the hydraulic system.
Page 6: Introduction
INTRODUCTION 1.3 INTRODUCTION 1.3.1 INTENDED USES The Komatsu Utility BACKHOE LOADERS described in this manual have been designed and constructed to be used mainly for the following functions: • LOADER • EXCAVATOR Through the installation of optional equipment, the machine can also be used for the following applications: •...
Page 7: Main Characteristics
INTRODUCTION 1.3.3 MAIN CHARACTERISTICS • Simple and easy operation. • Servo-assisted steering with priority hydraulic system. • Three steering modes that can be selected with a push button: - Two-wheel steering - All-wheel steering - Crab steering • Gearshift with electronic gear selection through solenoid valve actuators and transmission with hydraulic con- verter;...
Page 8: Product Identification
PRODUCT IDENTIFICATION 1.4 PRODUCT IDENTIFICATION The Komatsu Utility backhoe loader and its main components are identified by serial numbers stamped on the identification plates. The serial number and the identification numbers of the components are the only numbers that must be indicated to the Dealer when requiring assistance and ordering spare parts.
Page 9: Engine Serial Number And Exhaust Gas Emission Plate
PRODUCT IDENTIFICATION 1.4.3 ENGINE SERIAL NUMBER AND EX- HAUST GAS EMISSION PLATE The engine serial number is stamped on the plate positioned on the rear side of the tappet cover. RWAB0480 The plate regarding the exhaust emission regulations is applied to the front side of the tappet cover.
Page 10: Rear Axle Serial Number
PRODUCT IDENTIFICATION 1.4.6 TRANSMISSION SERIAL NUMBER The transmission serial number is stamped on the plate pos- tioned on the right side of the transmission case. RWA02540 1.4.7 CAB SERIAL NUMBER RWA02500 The cab serial number is stamped on the plate positioned on the right center pillar.
Page 11: Serial Numbers And Dealer's Address
PRODUCT IDENTIFICATION 1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS Machine n. Model Engine n. Front axle n. Rear axle n. Transmission n. Cab n. Canopy n. Dealer: Address: Tel. Person to contact: NOTES:...
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Page 13: Table Of Contents
TABLE OF CONTENTS Page TABLE OF CONTENTS FOREWORD ..............INFORMATION ON SAFETY .
Page 14 TABLE OF CONTENTS Page PRECAUTIONS TO BE TAKEN WHEN WORKING ........2.4.1 STARTING THE ENGINE .
Page 15 TABLE OF CONTENTS Page DESCRIPTION AND USE OF THE MACHINE SAFETY LOCKS..............3.1.1 FRONT LOADER LOCKS .
Page 16 TABLE OF CONTENTS Page 3.6.2 STARTING THE ENGINE ........... 3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES .
Page 17 TABLE OF CONTENTS Page MAINTENANCE GUIDE TO MAINTENANCE ............MAINTENANCE NOTES .
Page 18 TABLE OF CONTENTS Page 4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic biodegradable oil type HEES is used) ..4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION ......4.7.6.a CHECKING THE RADIATOR FLUID LEVEL .
Page 19 TABLE OF CONTENTS Page TECHNICAL SPECIFICATIONS TECHNICAL DATA............. . . 5.1.1 STANDARD OVERALL DIMENSIONS WITH CENTERED BACKHOE .
Page 20 TABLE OF CONTENTS Page ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER ....6.6.1 DESCRIPTION AND CONTROL ..........6.6.1.1 VERSION WITH STANDARD CONTROLS .
Page 21: Safety And Accident Prevention
SAFETY AND ACCIDENT PREVENTION...
Page 22: Safety, Noise And Vibration Plates
Do not use fuel, petrol or solvents. • If the plates are damaged, ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer. • In case of replacement of a component provided with a safety plate, make sure that this plate is applied also on the new piece.
Page 23 SAFETY, NOISE AND VIBRATION PLATES RWA26150 RWA00030 RWA00020 RWA00190 RWA00020 RWA00150 RWA00160 RWA37700...
Page 24: Pictograms And Relevant Meanings
SAFETY, NOISE AND VIBRATION PLATES 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS The warning and danger plates applied onto the machine are accompanied or represented by pictograms. The personnel in charge with the operation and maintenance of the machine must know the symbols contained in the pictograms perfectly;...
Page 25 SAFETY, NOISE AND VIBRATION PLATES CONSULT THE MANUAL • Carefully read the contents of the manual before using the ma- chine or performing maintenance operations. RWA00030 HYDRAULIC OIL TOPPING UP RWA00050 REFUELLING RWA00040 ENGINE LUBRICATING OIL FILTER RWA00080 FUEL FILTER RWA00060 ENGINE AIR SUCTION FILTER RWA00090...
Page 26 SAFETY, NOISE AND VIBRATION PLATES ENGINE COOLANT RWA00130 ENGINE COOLANT PRESSURE RWA00110 HYDRAULIC OIL LEVEL RWA00100 HYDRAULIC OIL FILTER RWA00070 ELECTRIC OUTLET 12 V RWA00120 TRANSMISSION OIL LEVEL RWA00180 HYDRAULIC TRANSMISSION OIL FILTER RWA00170...
Page 27 SAFETY, NOISE AND VIBRATION PLATES ANCHORAGE POINT RWA00200 EMERGENCY EXIT RWA00190 BOOM LOCK RWA00160 SWING LOCK RWA00150 BRAKE OIL RWA00140 DO NOT LIFT MORE THAN 1000 kg > 1000 Kg RWA00210...
Page 28: Position Of The Noise Plates On Machines With Cab
Do not use fuel, petrol or solvents. • If the plates are damaged, ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer. • In case of replacement of a component provided with a noise plate, make sure that this plate is applied also on the new piece.
Page 29: Vibrations To Which The Operator Is Subjected
SAFETY, NOISE AND VIBRATION PLATES 2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED • According to the results of the tests carried out to determine the vibrations transmitted to the operator by the machine, the upper limbs are subjected to vibrations lower than 2.5 m/sq.sec., while the seated part of the body is subject to vibrations lower than 0.5 m/sq.sec.
Page 30: General Precautions
GENERAL PRECAUTIONS 2.2 GENERAL PRECAUTIONS 2.2.1 GENERAL SAFETY RULES • Only trained and authorized personnel can use the machine and perform maintenance operations. • Follow all the safety rules, precautions and instructions when using the machine or performing maintenance op- erations.
Page 31: Unauthorized Modifications
2.2.4 UNAUTHORIZED MODIFICATIONS • Any modification made without the authorization of Komatsu Utility can involve hazards. • Before making a modification, consult your Komatsu Utility Dealer. Komatsu Utility declines any responsibility for injuries or damage caused by unauthorized modifications. 2.2.5 LEAVING THE OPERATOR’S SEAT •...
Page 32: Getting On And Off The Machine
GENERAL PRECAUTIONS 2.2.6 GETTING ON AND OFF THE MA- The cab CHINE • Do not jump on or off the machine, either when it is at rest and when it is moving. • When getting on or off the machine, always use the handles and the safety ladders;...
Page 33: Preventing Burns
GENERAL PRECAUTIONS • When refuelling, hold the fuel gun firmly and keep it constantly in contact with the filler until you have finished, in order to avoid sparks due to static electricity. • After topping up, tighten the fuel and oil safety caps securely. •...
Page 34: Preventing Damage Caused By The Work Equipment
• When installing and using optional equipment, carefully read the relevant instruction manual and keep to the in- dications given therein. • Do not use optional or special equipment without the authorization of Komatsu Utility or the Komatsu Utility Dealer.
Page 35: Precautions To Be Taken Before Starting The Engine
• Check the safety belt and change it if it is broken or damaged. Replace any component only with homologated parts available at Komatsu Utility or its Dealers. • Make always sure that the lock of the right door, which is considered the emergency door, is open.
Page 36: Room Ventilation
PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 2.3.4 ROOM VENTILATION • Before starting the machine in confined or poorly ventilated places, provide for proper ventilation or connect the engine ex- haust pipe to a suction duct. The engine exhaust gases can be deadly.
Page 37: Precautions To Be Taken When Working
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.1 STARTING THE ENGINE • Before getting on the machine, walk around it and check for people and objects that might be in the way. • Do not start the engine if warning plates have been attached to the steering wheel or the control levers. •...
Page 38: Checks For Travelling In Reverse
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.3 CHECKS FOR TRAVELLING IN RE- VERSE • When operating in areas that may be hazardous or have poor visibility, designate a person to direct the movements of the machine and traffic on the work site. •...
Page 39: Working On Slopes
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.5 WORKING ON SLOPES RWA25880 • Operations on slopes and on river or lake banks with damp ground may result in the tipping over or slipping of the ma- chine. 20÷30 cm • Do not work with the bucket downward with respect to the trac- tor.
Page 40: Preventing Electrocution
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.6 PREVENTING ELECTROCUTION • Digging operations near overhead electric lines are extremely dangerous and they may also cause death due to electrocu- tion; for this reason, when working near overhead electrical lines always respect the minimum safety distances prescribed by the competent authorities and by the accident-prevention rules in force.
Page 41: Visibility
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.7 VISIBILITY • Switch on the road or working lights as soon as visibility decreases. • If visibility decreases due to mist, smoke or heavy rain, stop the machine in a safe position and wait for the weather to improve until visibility becomes acceptable.
Page 42: Parking The Machine
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.11 PARKING THE MACHINE RWA26110 • Park the machine on firm and level ground. If this is not possi- ble and it is necessary to park on a slope, position the ma- chine with the front bucket directed downwards and carry out the following operations: 1 - While keeping the machine stopped with the brakes, apply the parking brake.
Page 43: Transporting The Machine On Other Vehicles
TRANSPORTING THE MACHINE ON OTHER VEHICLES 2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES 2.5.1 LOADING AND UNLOADING THE MACHINE • Loading and unloading the machine on/from a motor vehicle Ramps always involves potential hazards. Proceed with extreme care. • Perform loading and unloading on firm, level ground. Maintain a safety distance from the edges of ditches or from road sides.
Page 44: Battery
BATTERY 2.6 BATTERY 2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES • Electrolytic batteries contain sulphuric acid that can quickly burn the skin and corrode clothes making holes in the fabric. If you spill acid on yourself, immediately rinse the involved area with plenty of water.
Page 45: Precautions For Emergency Recovery
PRECAUTIONS FOR EMERGENCY RECOVERY 2.7 PRECAUTIONS FOR EMERGENCY RECOVERY • The draw hooks must be used only for the first aid and not for towing the machine. • Before moving the machine, make sure that the gearshift lever is in neutral and disengage the four-wheel drive. •...
Page 46: Precautions To Be Taken During Maintenance
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.1 WARNING PLATES • Before starting any maintenance operation, position the ma- chine on firm and level ground, engage the safety locks either for the equipment and the controls, stop the engine and apply the parking brake.
Page 47: Equipment
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.4 EQUIPMENT • The normal or special equipment that must be installed on the machine or that have been removed must be stored in safe places, preventing them from falling down. If they fall on some- one, they can cause serious bodily harm.
Page 48: Use Of The Engine During Maintenance
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.7 USE OF THE ENGINE DURING MAINTENANCE • During maintenance operations, let the engine run only when indispensable. If it is necessary to have the en- gine running (for example, to wash the cooling circuit or to check the functionality of the alternator), an operator should constantly remain in the cab, in order to be able to stop the engine whenever necessary.
Page 49: Stop The Engine Before Carrying Out Any Maintenance Operation
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.9 STOP THE ENGINE BEFORE CAR- RYING OUT ANY MAINTENANCE OPERATION OR INSPECTION • Stop the machine only on firm and level ground and stop the engine before carrying out any maintenance operation or in- spection.
Page 50: Rules For Refuelling And Adding Oil
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.10 RULES FOR REFUELLING AND ADDING OIL • Spilled fuel or oil make the ground slippery and may cause ac- cidents; clean any dirty area immediately and carefully. • Always tighten the fuel tank and hydraulic circuit oil safety caps securely.
Page 51: Precautions Concerning The Battery And The Alternator
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.13 PRECAUTIONS CONCERNING THE REMOVAL BATTERY AND THE ALTERNATOR • When repairing the electrical system, disconnet the battery in order to stop the flow of current. IMPORTANT • Disconnect first the negative earth cable (-) and then the positive cable (+).
Page 52: Precautions Concerning The Gearshift
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.15 PRECAUTIONS CONCERNING THE GEARSHIFT • If electrical welding operations are to be carried out on the ma- chine, it is necessary to disconnect the connector (1) of the gearshift unit positioned under the steering wheel. To reach the connector (1), first remove the protection casing (2).
Page 53: Precautions For Maintenance Work Involving High Temperatures
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.18 PRECAUTIONS FOR MAINTE- NANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES • When the machine is stopped at the end of operations, the en- gine coolant, the oil and all the components are hot and the hydralic circuits are under pressure.
Page 54: Precautions To Be Taken When Inflating Tyres
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.21 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES • When being inflated, the tyres may explode and come off, thus causing serious accidents. • Before inflating the tyres, always check the conditions of the rims and the outer conditions of the tyres themselves, in order make sure that there are no dents, cuts, torn plies or other de- fects.
Page 55: Type Hees
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.23 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADA- BLE OIL TYPE HEES • 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).
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Page 57 THE MACHINE AND ITS OPERATIONS...
Page 58: Safety Locks
SAFETY LOCKS 3.1 SAFETY LOCKS DANGER • If it is necessary to carry out maintenance operations or to stop the machine with raised loader arm, always en- gage the mechanical safety lock and the control lever lock. • When travelling on roads, always engage the mechanical lock, lock the control lever in order to keep the front buck- et in a stable position and use the front bucket antirota- tion lock and the teeth protection.
Page 59 SAFETY LOCKS RWA04370 The other applications of the safety locks concern: a) Installation of the front bucket swing lock (1). b) Engaging of the front loader (2) control lever lock. c) Installation of the teeth protection casing (3). RWAA0770 RWA26220 RWA31270...
Page 60: Backhoe Locks
SAFETY LOCKS 3.1.2 BACKHOE LOCKS The backhoe is held completely raised by a single coupling that does not permit the lowering of the boom. The other safety device regards the swing, which is locked, ei- ther in the central and in the folded position, by means of a pin. To lock the boom, proceed as follows: 1 - Fold the bucket and arm completely.
Page 61: General Views
GENERAL VIEWS 3.2 GENERAL VIEWS 3.2.1 FRONT GENERAL VIEW RWA26240 RIGHT FORWARD LEFT 1 - Front bucket 5 - Rear axle 2 - Bucket dumping cylinder 6 - Fuel tank 3 - Bucket lifting arm 7 - Lifting cylinder 4 - Cab 8 - Front axle...
Page 62: Backhoe General View
GENERAL VIEWS 3.2.2 BACKHOE GENERAL VIEW RWA26350 RIGHT FORWARD LEFT 1 - Bucket 8 - Stabilizers 2 - Bucket cylinder 9 - Backhoe sliding guides 3 - Arm 10 - Backhoe locking cylinders 4 - Boom 11 - Boom swing cylinders 5 - Arm cylinder 12 - Sliding plate 6 - Boom cylinder...
Page 63: Cab Inside General View
GENERAL VIEWS 3.2.3 CAB INSIDE GENERAL VIEW 3.2.3.1 CAB INSIDE GENERAL VIEW (Standard version) RWA16630 RWA34820 1 - Reversing gear-gearshift control lever RWA16650 2 - Steering wheel 3 - Front dashboard 4 - Direction selector - dimmer switch 5 - Steering wheel adjustment lock 6 - Front loader control lever 7 - Accelerator pedal 8 - Brake pedals...
Page 64: Cab Inside General View (Version With Servcontrols Available On Request)
INSTRUMENTS AND CONTROLS 3.2.3.2 CAB INSIDE GENERAL VIEW (Version with servcontrols available on request) RWA16630 RWA38250 1 - Reversing gear-gearshift control lever RWA16650 2 - Steering wheel 3 - Front dashboard 4 - Direction selector - dimmer switch 5 - Steering wheel adjustment lock 6 - Front loader control lever 7 - Accelerator pedal 8 - Brake pedals...
Page 65: Instruments And Controls
INSTRUMENTS AND CONTROLS 3.3 INSTRUMENTS AND CONTROLS 3.3.1 FRONT INSTRUMENTS 1 - Transmission oil temperature warning RWA27790 light 2 - Engine coolant temperature warning 4 17 light 3 - Four-wheel drive engagement warning light 4 - Low fuel warning light 5 - Direction indicator warning light 6 - High beam warning light 7 - Parking brake and brake oil level warn-...
Page 66 INSTRUMENTS AND CONTROLS DIRECTION INDICATOR WARNING LIGHT This warning light comes on intermittently when the lever (9) or the emergency switch - pos. 13 - are operated. HIGH BEAM WARNING LIGHT RWA26470 It comes on when the high beam is operated through the dimmer switch - pos.
Page 67 INSTRUMENTS AND CONTROLS 11 - FRONT WINDSHIELD WIPER / WASHER SWITCH With the first click it operates the windshield wiper, while with the second click (with automatic return to the first) it operates the windshield washer. 12 - FRONT WORKING LIGHT SWITCH This switch enables the front working light circuit.
Page 68 INSTRUMENTS AND CONTROLS 17 - ELECTRONIC DISPLAY The electronic display (17) shows the alignment of the front and rear axles, besides managing and displaying several functions, at the same time controlling them completely and effectively: • speedometer, with indication in km/h and Mp/h; •...
Page 69 INSTRUMENTS AND CONTROLS 3 - Maintenance plan The display shows the maintenance plan in the following order: • Maintenance operations to be performed every 500 hours (en- gine oil, fuel filter, air cleaner and engine oil filter). 500H RWA26520 • Maintenance operations to be performed every 1000 hours (transmission filter).
Page 70 INSTRUMENTS AND CONTROLS When a maintenance alarm is sent out, the display (17) keeps showing the speedometer together with the ”CHECK” signal (see figure A or B). 000KM/h CHECK RWA26550 000MP/h CHECK RWA26560 By pressing the CHECK button (1), it is possible to display what maintenance operation must be performed.
Page 71 INSTRUMENTS AND CONTROLS • Every 1000 hours: - Transmission filter (Fig. G) • Every 2000 hours: 500H FUEL - Brake oil (Fig. H) FILTER - Coolant (Fig. I) - Hydraulic oil (Fig. L). To return to the speedometer, press the CHECK button (1) again.
Page 72 INSTRUMENTS AND CONTROLS 4 - Language selection It is possible to display the list of all the languages available, in the following order: • Italian • English • German • French • Spanish • Portuguese RWA26820 IMPORTANT • To select a language, move to the desired page by press- ing the SERVICE button (2).
Page 73 INSTRUMENTS AND CONTROLS 7 - Operation alarms Besides the functions described before, the display (17) has also the function to warn the operator in case of problems on some machine components. These alarms take priority over any other message displayed (maintenance alarms) and are accompanied by an acoustic sig- nal.
Page 74 INSTRUMENTS AND CONTROLS If a malfunction should be found in the steering solenoid valves, the relevant message will appear on the display (17) and an acoustic signal will be sent forth, according to the solenoid valve presenting the failure. • Crab steering solenoid valve failure. RWA27260 •...
Page 75 INSTRUMENTS AND CONTROLS • Rear potentiometer failure RWA27570 Other operation alarms that can be shown on the display (17) are the following: • Alternator failure. RWA27870 • Insufficient engine oil pressure. RWA27890 • Maximum coolant temperature. RWA27900...
Page 76 INSTRUMENTS AND CONTROLS • Air cleaner clogging. RWA27910 • Converter oil maximum temperature. IMPORTANT • When an operation alarm is sent forth, stop the machine, engage all the safety locks and carry out the necessary re- pair. • The acoustic alarm sends out two different sounds: an in- termittent sound for the steering alarms and a continuous sound for all the other types of alarm.
Page 77: Side Instruments
INSTRUMENTS AND CONTROLS 3.3.2 SIDE INSTRUMENTS 3.3.2.1 SIDE INSTRUMENTS (Standard version) 1 - Fuel level indicator 2 - Revolution counter - Hour meter 3 - Engine coolant temperature indicator 4 - Air cleaner clogging warning light 5 - Engine oil pressure warning light 6 - Glow plug preheating warning light 7 - Generator warning light 8 - Engine coolant temperature warning...
Page 78: Side Instruments (Version With Servo Controls Available On Request)
INSTRUMENTS AND CONTROLS 3.3.2.2 SIDE INSTRUMENTS (Version with servo controls available on request) 1 - Fuel level indicator 2 - Revolution counter - Hour meter 19 20 3 - Engine coolant temperature indicator 4 - Air cleaner clogging warning light 5 - Engine oil pressure warning light 6 - Glow plug preheating warning light 7 - Generator warning light...
Page 79 INSTRUMENTS AND CONTROLS FUEL LEVEL INDICATOR RWA02620 It indicates the fuel level in the tank; this indication is given only when the ignition key is in position «I» (see pos. 17). RPM x 100 electronic REVOLUTION COUNTER - HOUR METER RWA02630 This is a combined instrument that indicates the engine running speed with a pointer, while the number of operating hours ap-...
Page 80 INSTRUMENTS AND CONTROLS AIR CLEANER CLOGGING WARNING LIGHT This warning light comes on and the acoustic alarm sounds when the engine air filter needs cleaning. When the warning light (4) comes on, the operator is warned about the inconvenience even through the electronic display positioned on the front dash- board.
Page 81 • Incorrect gear selection with respect to the selected steering mode. IMPORTANT • Before using the machine, make sure that the acoustic alarm (10) functions perfectly. If the alarm doesn’t work, have the machine checked by your Komatsu Utility Dealer.
Page 82 INSTRUMENTS AND CONTROLS 11 - REAR WORKING LIGHT SWITCH This switch enables the rear working light circuit. IMPORTANT • When travelling on roads, turn off the working lights. 12 - REAR WINDSHIELD WIPER / WASHER SWITCH RPM x 100 electronic With the first click it operates the windshield wiper, while with the second click (with automatic return to the first) it operates the windshield washer.
Page 83 INSTRUMENTS AND CONTROLS 17 - IGNITION SWITCH The ignition switch is a rotary key switch with four positions marked with the following symbols: « » - (OFF) - I - « » (START). For further details on the use of this switch see “3.6.2 START- ING THE ENGINE”).
Page 84 INSTRUMENTS AND CONTROLS 19 - BACKHOE SPEED CONTROL BUTTON This button permits the selection of the oil delivery of the hydrau- POWER lic pump. Whenever restarted, the machine automatically selects the POWER mode (LED on), even if when it stopped the select- ed mode was ECONOMY.
Page 85 INSTRUMENTS AND CONTROLS 22 - BACKHOE CONTROL LOCKING SWITCH (Version with servo controls only) This switch has the specific function to disable all the backhoe controls and this function must always be activated when the backhoe is not used or when travelling on roads. To activate the control locking function, press the switch (22).
Page 86: Push Buttons On The Front Loader Control Lever
INSTRUMENTS AND CONTROLS 3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER 1 - Declutch push button 2 - Available push button 3 - 4in1 bucket opening push button 4 - 4in1 bucket folding push button 5 - Front loader speed control push button 6 - KICK-DOWN push button RWA31280 DECLUTCH PUSH BUTTON...
Page 87: Electrical Accessories
INSTRUMENTS AND CONTROLS 3.3.4 ELECTRICAL ACCESSORIES OVERHEAD LAMP The overhead lamp is used to check the instruments and the in- side of the cab when visibility is scarce. RWAA0230 ELECTRIC OUTLET The electric outlet is a 12V outlet in compliance with the ISO 4165-1979 standard.
Page 88: Machine Controls
INSTRUMENTS AND CONTROLS 3.3.5 MACHINE CONTROLS 3.3.5.1 MACHINE CONTROLS (Standard version) RWA38270 RWA34890 1 - Reversing gear-gearshift lever 2 - Steering selector unit 3 - Brake pedals 4 - Accelerator 5 - Front loader control lever 6 - KICK-DOWN push button 7 - Parking brake 8 - Hand accelerator 9 - Backhoe boom lock control switch...
Page 89: Machine Controls (Version With Servo Controls Available Upon Request)
INSTRUMENTS AND CONTROLS 3.3.5.2 MACHINE CONTROLS (Version with servo controls available upon request) RWA38270 RWA38280 9 10 1 - Reversing gear-gearshift lever 2 - Steering selector unit 3 - Brake pedals 4 - Accelerator 5 - Front loader control lever 6 - KICK-DOWN push button 7 - Parking brake 8 - Hand accelerator...
Page 90 INSTRUMENTS AND CONTROLS RWA38550 20 - Left joystick locking lever (only with servo control system) 21 - Right joystick locking lever (only with servo control system) 22 - Left support adjusting knob (only with servo control system) 23 - Right support adjusting knob (only with servo control system) 24 - Left joystick stroke adjusting knob (only with servo control system)
Page 91 - Press the brake pedals. - Shift the reversing gear lever (1) to the reverse position If the alarm doesn’t work, have the machine checked by your Komatsu Utility Dealer. This is a combined control that serves either to shift gears and to reverse.
Page 92 INSTRUMENTS AND CONTROLS MAIN FUNCTIONS OF THE GEARSHIFT CONTROL RWA12420 1 - Reversing gear lever for the forward (FWD), reverse (REV) and NEUTRAL (N) selection. 2 - (UP) push button for the upshifting. 3 - (DOWN) push button for the downshifting. 4 - Red led (N);...
Page 93 INSTRUMENTS AND CONTROLS STARTING THE ENGINE • Shift the lever to the neutral position (N), turn the ignition key to position «I» and make sure that the display indicates (88). Start the engine. After a quick self-test phase, the 2 gear with semi- automatic logic (SA) will be shown on the display (15).
Page 94 INSTRUMENTS AND CONTROLS DIM PUSH BUTTON (12) • This push button confirms and acquires the anti-theft code. The 4 digits of the secret code must be entered in sequence and each selection must be confirmed by means of the push button 12 (DIM).
Page 95 INSTRUMENTS AND CONTROLS • If the gears are shifted at unsuitable speed, the flashing led (13) comes on and this is signalled by a long beep (1 sec). The electronic control does not carry out the shifting, but stores the selection. When the speed is optimal, the led stops flashing and the se- lected gear is engaged.
Page 96 INSTRUMENTS AND CONTROLS GEAR SHIFTING WITH AUTOMATIC LOGIC (AU) • After the connection of the automatic function (AUT button 11), the electronic control always sets on the 2 gear; engage the forward or reverse gear within the following three seconds. •...
Page 97 INSTRUMENTS AND CONTROLS KICK-DOWN FUNCTION FOR 1 AND 2 GEAR ONLY • A pulse push button (1) positioned on the front loader control lever and connected to the electronic control engages the 1 gear from the 2 or the 2 from the 1st and maintains the se- lected gear.
Page 98 7 volts, electronic card anomaly. RWA12550 CAUTION • When a figure code appears on the display, contact your Komatsu Utility Dealer or an Komatsu Utility authorized repair shop for the necessary checks and repairs. DIAGNOSTIC FUNCTION FOR ANOMALIES - MA- CHINE WORKING Condition during the self-test phase.
Page 99 INSTRUMENTS AND CONTROLS STEERING SELECTOR UNIT DANGER • The selection of the crab steering must be carried out with the machine at rest and only in 1 and 2 gear, while the selection of the all-wheel steering can be performed even with the machine moving and only in 1 and 3 gear.
Page 100 INSTRUMENTS AND CONTROLS The display (17) indicates which wheels must be aligned through the relevant symbols: - Front wheels misaligned (see Fig. d). - Rear wheels misaligned (see Fig. e). Once the wheels are aligned, the relevant symbols go out and the acoustic alarm stops.
Page 101 INSTRUMENTS AND CONTROLS SWITCHING OVER FROM ONE STEERING MODE TO THE OTHER • SWITCHING OVER FROM TWO-WHEEL STEERING TO ALL-WHEEL STEERING Press buttons (1) and (2) at the same time and turn the steering wheel clockwise or anticlockwise to align the front wheels. The misalignment of the front wheels is signalled by the acoustic alarm, which will stop once the wheels are correctly aligned.
Page 102 INSTRUMENTS AND CONTROLS • SWITCHING OVER FROM ALL-WHEEL STEERING TO TWO-WHEEL STEERING Press only button (1) and turn the steering wheel clockwise or anticlockwise to align the rear wheels. The misalignment of the wheels is signalled by the acoustic alarm, which will stop as soon as the wheels are correctly aligned.
Page 103 INSTRUMENTS AND CONTROLS • SWITCHING OVER FROM ALL-WHEEL STEERING TO CRAB STEERING Press buttons (1) and (3) at the same time and turn the steering wheel clockwise or anticlockwise to align the rear wheels. The misalignment of the rear wheels is signalled by the acoustic alarm, which will stop as soon as the wheels are correctly aligned.
Page 104 INSTRUMENTS AND CONTROLS • SWITCHING OVER FROM CRAB STEERING TO TWO- WHEEL STEERING Press only button (1) and turn the steering wheel clockwise or anticlockwise to align the rear wheels. The misalignment of the wheels is signalled by the acoustic alarm, which will stop as soon as the wheels are correctly aligned.
Page 105 INSTRUMENTS AND CONTROLS • SWITCHING OVER FROM CRAB STEERING TO ALL- WHEEL STEERING Press buttons 1 and 2 at the same time and turn the steering wheel clockwise or anticlockwise to align the rear wheels. The misalignment of the wheels is signalled by the acoustic alarm, which will stop as soon as the wheels are correctly aligned.
Page 106 INSTRUMENTS AND CONTROLS BRAKE PEDALS DANGER • The brake pedals must always be connected in 3 and 4 gear and when the machine travels on roads. • Non-compliance with this rule may result in serious acci- dents. The machine is provided with two split brake pedals that make it possible to turn sharply in small work areas with many obsta- RWA28320 cles;...
Page 107 INSTRUMENTS AND CONTROLS FRONT LOADER CONTROL LEVER DANGER • Before carrying out any operation with this lever, the oper- ator must be sitting in the driving position with fastened seat belt. • If the loader control lever has to be used during travel, avoid any abrupt and quick movement that may affect the balance of the machine and make it difficult to drive.
Page 108 INSTRUMENTS AND CONTROLS If the lever is operated in directions that are inclined with respect RWA00550 to the machine axes, simultaneous movements proportional to the angle of inclination are obtained, since the two hydraulic dis- tributors corresponding to each single function are engaged at the same time.
Page 109 INSTRUMENTS AND CONTROLS KICK-DOWN PUSH BUTTON This is a pulse push button connected to the electronic control of the transmission and can be used only in 1 or 2 gear. In 1 gear, the button (6) selects the 2 gear and keeps it en- gaged.
Page 110 INSTRUMENTS AND CONTROLS HAND ACCELERATOR DANGER • The use of the hand accelerator is allowed only under the conditions indicated; use in any other condition may cause accidents. The hand accelerator can be used only when the engine is warming up and successively only when it is necessary to work with the backhoe;...
Page 111 INSTRUMENTS AND CONTROLS BACKHOE BOOM LOCK CONTROL SWITCH DANGER • Always engage the boom safety lock when the backhoe is not used and when travelling on roads. This is a two-position switch and is used to connect the boom to the safety lock (A).
Page 112 INSTRUMENTS AND CONTROLS 10 - BACKHOE SLIDING LOCK CONTROL RWA28170 SWITCH The switch (10) has the function to release the pressure neces- sary to lock the backhoe unit, so that the backhoe can slide on the guides. With released switch (led off) the backhoe unit is locked on the guides.
Page 113 INSTRUMENTS AND CONTROLS 12 - 4IN1 BUCKET OPENING PUSH BUTTON On the machines provided with the 4in1 bucket, the distributor for the opening of the bucket is controlled through the push but- ton (12) positioned on the loader control lever. Press the button to open the bucket;...
Page 114 INSTRUMENTS AND CONTROLS 15/16 - BACKHOE CONTROL LEVERS (Standard version) DANGER • Before carrying out any manoeuvre with these levers, the operator must be sitting in the working position, that is, with the seat rotated by 180° with respect to the driving position and with fastened safety belt;...
Page 115 INSTRUMENTS AND CONTROLS 16/17 - BACKHOE CONTROL LEVERS (Version with servo controls available on request) IMPORTANT • Before carrying out any manoeuvre with these levers, the operator must be sitting in the working position, that is, with the seat rotated by 180° with respect to the driving position and with fastened safety belt;...
Page 116 INSTRUMENTS AND CONTROLS To use the backhoe control levers correctly, proceed as follows: 1 - With the machine at rest and the engine off, seat on the driv- er’s seat and rotate it by 180° with respect to the driving posi- tion.
Page 117 INSTRUMENTS AND CONTROLS ISO STANDARD CONTROLS LEVER 15 (BASIC MANOEUVRES) RWA00600 N - Neutral A - Boom swing to the left B - Arm opening C - Boom swing to the right D - Arm folding LEVER 16 (BASIC MANOEUVRES) RWA00610 N - Neutral A - Bucket folding...
Page 118 INSTRUMENTS AND CONTROLS KOMATSU SYSTEM CONTROLS LEVER 15 (BASIC MANOEUVRES) RWA00560 N - Neutral A - Boom swing to the left B - Boom lowering C - Boom swing to the right D - Boom raising LEVER 16 (BASIC MANOEUVRES) RWA00570 N - Neutral A - Bucket folding...
Page 119 INSTRUMENTS AND CONTROLS “X” SYSTEM CONTROLS LEVER 15 (BASIC MANOEUVRES) RWA00640 N - Neutral A - Boom swing to the left B - Boom lowering C - Boom swing to the right D- Boom raising LEVER 16 (BASIC MANOEUVRES) RWA00650 N - Neutral A - Arm opening B - Bucket opening...
Page 120 INSTRUMENTS AND CONTROLS 17/18 - STABILIZER CONTROL LEVERS (Standard version) IMPORTANT • Before moving the machine, make sure that the stabilizers are completely raised. • When travelling on roads, raise the stabilizers completely and engage the safety locks. These levers control the lowering and raising of the machine sta- RWA35350 bilizers during digging operations.
Page 121 INSTRUMENTS AND CONTROLS 19 - STEERING WHEEL ADJUSTMENT LOCKING LEVER DANGER • Adjust the steering wheel while seated in the driving posi- tion. The machine must be completely still and the engine must be off. • Before using the machine, make sure that both the steer- ing wheel and the adjusting lever are completely locked.
Page 122 INSTRUMENTS AND CONTROLS 20-21 JOYSTICK LOCKING LEVERS (Only with servo controls) 20 21 DANGER • The operator must use the joystick locking levers while seated in the driving position, with the machine at rest. • Before using these levers, always make sure that the backhoe control locking device is engaged.
Page 123 INSTRUMENTS AND CONTROLS 24-25 JOYSTICK STROKE ADJUSTING KNOB (On- ly with servo controls) DANGER • The adjustment of the joystick stroke must be carried out before starting work and with the machine completely still. • Before adjusting these knobs, always make sure that the backhoe control locking device is engaged.
Page 124 INSTRUMENTS AND CONTROLS 26 - BACKHOE CONTROL LOCKING SWITCH (Only with servo controls) DANGER • If it is necessary to stop the machine, lower the equipment to the ground and always engage the control safety device by means of the locking switch (27). •...
Page 125 INSTRUMENTS AND CONTROLS 27 - OFFSET BOOM LEFT SWING CONTROL PUSH BUTTON (if installed and only with servo controls) This is a single-function push button positioned on the left joy- stick lever and allows the offset boom to be swung to the left. To swing the boom, press the push button (27);...
Page 126 INSTRUMENTS AND CONTROLS 29 - HORN PUSH BUTTON (Only with servo controls) This push button is positioned on the left backhoe control lever and serves to warn the persons in the vicinity at the beginning of the operations and in case of danger when working with the backhoe.
Page 127 INSTRUMENTS AND CONTROLS 31 - TELESCOPIC ARM RETRACTION PUSH BUT- TON (if installed and only with servo controls) This is a single-function push button positioned on the right joy- stick lever and controls the retraction of the telescopic arm. To retract the arm, press the push button (31);...
Page 128 INSTRUMENTS AND CONTROLS 33 - PATTERN CHANGE CONTROL LEVER (if installed and only with servo controls) DANGER • The desired control pattern must be selected before start- ing work, with the machine completely still. • Before using the controls, the operator must make sure that the selected pattern is the one required.
Page 129: Fuses And Relays
FUSES AND RELAYS 3.4 FUSES AND RELAYS IMPORTANT • When changing a fuse, make sure that the ignition switch is in position « ». • If the fuses are oxidized, corroded or do not fit perfectly in their seat, replace them only with new fuses having the same capacity.
Page 130: Fuses
FUSES AND RELAYS DL20 DL23 DL28 DL10 DL14 DL17 DL11 DL13 DL15 DL18 DL21 DL24 DL29 DL19 DL22 DL25 DL12 DL27 K2 K4 DL16 RWA35380 3.4.1.1 FUSES POSITION COLOUR CAPACITY (A) INVOLVED CIRCUIT Light blue Low beam Violet Rear right and front left parking light Violet Rear left and front right parking light EGM power supply - Four-wheel drive...
Page 131: Relays
FUSES AND RELAYS 3.4.1.2 RELAYS POSITION DESCRIPTION Reversing gear acoustic alarm (if installed) Four-wheel drive relay Start enabling relay Low beam relay High beam relay Horn relay Blinking relay EGM power supply relay 3.4.2 ENGINE LINE FUSES AND RELAYS The fuses and relays are grouped on a single base positioned inside the engine compartment and protected by a cover (1).
Page 132: Fuses
FUSES AND RELAYS RWA38210 3.4.2.1 FUSES POSITION COLOUR CAPACITY (A) INVOLVED CIRCUIT Blue Key block power supply White Engine stop Orange Engine start circuit Orange Heating and air conditioning fan - High and low beam - Electric outlet 3.4.2.2 RELAYS POSITION DESCRIPTION Engine stop enabling timer...
Page 133: Side Dashboard Relays
FUSES AND RELAYS 3.4.3 SIDE DASHBOARD RELAYS POSITION DESCRIPTION 4 5 6 Stop light relay Seat safety relay Automatic power relay Return-to-dig relay (if installed) Fan 3 speed relay (only with A/C system) Fan relay These relays are positioned inside the right dashboard; to reach them, lift the dashboard cover (7), after removing the relevant fastening screws (8).
Page 134: Guards, Cab And Driver's Seat
3.5.2 CANOPY (if provided) DANGER • The safety canopy (1) is ROPS-FOPS homologated; if it is subjected to an impact for any reason, or if the machine overturns, contact your Komatsu Utility Distributor imme- diately to have the canopy replaced. RWA28190...
Page 135: Cab
• The cab is ROPS-FOPS homologated; if it is subjected to an impact for any reason, or if the machine overturns, contact your Komatsu Utility Distributor immediately to have the cab replaced. • The cab is provided with two doors; the left door must be normally used to get on and off the cab, while the right door is the emergency door.
Page 136 GUARDS, CAB AND DRIVER’S SEAT The rear side windows can be opened partially or completely. To open them partially, proceed as follows: 1 - Release the lever (3) from the lower coupling pin (4), follow- ing the direction indicated by the arrow shown in Fig. A. RWAB0170 2 - Lift the lever (3) with a simple sliding movement and at the same time push the lever toward the outside of the cab.
Page 137 GUARDS, CAB AND DRIVER’S SEAT 3 - Rotate the rear side windows towards the front of the ma- chine, until engaging the coupling (6) in the rubber block (7), as shown in Fig. E. To close the rear side windows, repeat the operations described above in the reverse order, remembering that the lever (3) must always be engaged in the lower coupling pin (4) as shown in Fig.
Page 138: Ventilation And Heating
GUARDS, CAB AND DRIVER’S SEAT 3.5.4 VENTILATION AND HEATING The ventilation and heating of the cab serve to reduce the oper- ator’s stress either in the summer and in the winter; these func- tions also serve to eliminate the condensate from the front window, thus ensuring visibility during both work and travel.
Page 139: Air Conditioner (If Installed)
• For specific maintenance operations to be performed on the air conditioning system, contact your Komatsu Utility Dealer. Non-compliance with these instructions may cause serious damage and even death. RWA33750...
Page 140 GUARDS, CAB AND DRIVER’S SEAT IMPORTANT • Periodically clean the filters, with time intervals to be fixed according to the environment in which the machine oper- ates (min. every 5 days - max. every 15 days). To clean the filters, see “4.7.1.b CAB AIR FILTER” and “4.7.1.c RECIR- CULATING AIR FILTER”.
Page 141: Seat
GUARDS, CAB AND DRIVER’S SEAT 3.5.6 SEAT 3.5.6.1 SEAT (STANDARD) The seat is extremely comfortable, in fact it offers five adjust- ment options: a - Longitudinal adjustment. b - Back inclination adjustment. c - Adjustment of the suspension, to dampen the inevitable vi- brations and jumps as much as possible.
Page 142: Seat (Optional)
GUARDS, CAB AND DRIVER’S SEAT 3.5.6.2 SEAT (OPTIONAL) The seat is really comfortable, in fact it features six different ad- justment options: longitudinal position; back inclination; degree of suspension, in order to cushion the inevitable vi- brations and jumps as much as possible; height and cushion inclination;...
Page 143: Safety Belt
GUARDS, CAB AND DRIVER’S SEAT 3.5.7 SAFETY BELT DANGER • Fasten the safety belt before starting the engine. • The safety belt must be changed when it is frayed, dam- aged or worn, or in any case every 4 years. The safety belt (1) is of the type with two coupling points and ad- justment of the length (2);...
Page 144: Additional Tool Box (If Provided)
GUARDS, CAB AND DRIVER’S SEAT 3.5.11 ADDITIONAL TOOL BOX (if provided) If the operator deems it necessary, an additional tool box (1) can be installed on the rear outer part of the cab. The box (1) can be used to store specific tools to be used for some maintenance op- erations or other tools that may be useful for the operator.
Page 145: Use Of The Machine
• 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 Komatsu Utility Dealer. Before starting the engine, check around and under the machine to verify: 1 - if there are loose screws or nuts;...
Page 146: Operational Checks
USE OF THE MACHINE 3.6.1.3 OPERATIONAL CHECKS DANGER • All the checks must be carried out by the operator while seated, with fastened safety belt. • When the machine is at rest after use or maintenance, some safety locks may not be engaged; when the opera- tor gets into the cab, he must make sure that all the me- chanical safety locks are engaged and that the equipment cannot move suddenly and create dangerous situations.
Page 147 USE OF THE MACHINE 3.6.2 STARTING THE ENGINE DANGER • Before starting the engine, carefully read the instructions and information regarding safety given in this manual and make sure that you know the controls. From the moment in which the engine is started, the operator is directly responsible for any damage that may be caused by wrong manoeuvres and non-compliance with the safety regulations and the rule of the road.
Page 148 USE OF THE MACHINE 3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES DANGER • Do not use any fluid or product that facilitate the cold starting of the engine, since these are ether-based and may cause explosions. 1 - Turn the key to the preheating position « »...
Page 149 USE OF THE MACHINE 3.6.3 WARMING THE ENGINE 1 - After starting the engine, let it warm up before starting work. 2 - The ideal warming up of the engine is achieved with a constant speed of 1200 rpm, obtained with the hand ac- celerator (see “3.3.5 pos.
Page 150 USE OF THE MACHINE 3.6.5 HOW TO MOVE THE MACHINE DANGER • Before moving the machine, make sure that you know the control functions and all the relevant safety regulations perfectly. • The operator must be sitting in the driving position with fastened safety belt and must have checked the position of the rear-view mirrors.
Page 151 USE OF THE MACHINE 3.6.5.1 ENGAGING THE FOUR-WHEEL DRIVE DANGER • The four-wheel drive must be engaged only with machine at rest or travelling at low speed. • The four-wheel drive can be engaged only in 1 or 2 gear; when the other gears are engaged, the four-wheel drive cannot be connected.
Page 152 USE OF THE MACHINE 3.6.5.2 MOVING ON SLOPES RWA28200 DANGER • Before starting to work on slopes, always check the func- tionality of the brakes and of the parking brake. • Always engage the four-wheel drive. • Avoid engaging the high gears. •...
Page 153 USE OF THE MACHINE 3.6.5.3 MAXIMUM IMMERSION DEPTH DANGER • If it is necessary to work with the machine immersed in water on on river banks or sea shores, always check the water depth and the current flow. • Make sure that the surface on which you are working is sufficently firm. If it is necessary to work with the machine immersed in water, make sure that the maximum depth does not ex- ceed 50 cm and in any case that the engine cooling fan does not touch the water, since it may get damaged or even break.
Page 154 PARKING THE MACHINE 3.7 PARKING THE MACHINE 3.7.1 PARKING ON LEVEL GROUND DANGER • Park the machine on firm and flat ground, in a sufficiently wide space, so that the checks, daily lubrication and refu- elling can be carried out without problems. •...
Page 155 PARKING THE MACHINE 3.7.2 PARKING ON SLOPES RWA26110 DANGER • The movement of the machine when the operator is not on board may cause serious accidents and even death; to prevent this, carry out the operations described below. • Park on slopes only when it is absolutely necessary. •...
Page 156 STOPPING THE ENGINE 3.8 STOPPING THE ENGINE IMPORTANT • The sudden stop of the engine while it is running short- ens its life. Do not stop the engine suddenly, except in case of emergency. • It is likewise recommended not to stop the engine sud- denly if it has been running for a long period and is still hot;...
Page 157 TRANSPORTING THE MACHINE ON OTHER VEHICLES 3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES 3.9.1 LOADING AND UNLOADING THE MACHINE DANGER • The loading and unloading of the machine on/from the means of transport must be carried out on a flat surface and at a safety distance from the edges of ditches or from the road side.
Page 158 TRANSPORTING THE MACHINE ON OTHER VEHICLES 6 - Fix the machine with tie-downs or chains (5) in the anchorage points (A - B) indicated by the pictograms (see “2.1.1 POSI- TION OF THE SAFETY PLATES”). 7 - Protect the end of the exhaust pipe (6). RWA28250 RWA01950 3.9.2 TRANSPORT...
Page 159 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON During the cold season or in areas where the temperature is particularly low, especially during the night, it is nec- essary to take some countermeasures meant to limit the damage deriving from low temperatures. 3.10.1 FUEL AND LUBRICANTS 1 - Change the fuel and use the winter fuel ASTM D975 N.
Page 160 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 1 - When the ambient temperature decreases, the battery capacity decreases accordingly and, if the battery charge is low, the electrolyte may freeze. Keep the battery completely charged and insulate it to protect it from low temperatures, so that the machine can be started without problems the following day.
Page 161 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 1 - At the end of the cold season, change the lubricants, the coolant and the fuel. IMPORTANT • The coolant must be changed only if it is not permanent. For the relevant specifications, see “4.3 FUEL, COOLANT AND LUBRICANTS”.
Page 162 USING THE MACHINE AS A LOADER 3.12 USING THE MACHINE AS A LOADER DANGER • Always fasten the safety belt. • When the declutch push button is used, the machine keeps moving in neutral; to stop it, put on the brakes.
Page 163 USING THE MACHINE AS A LOADER 3.12.2.1 LOADING HEAPED AND LEVEL MATERI- RWA28270 The efficiency of the bucket depends on how the operator starts loading; proceed as follows: 1 - Start moving and direct the bucket towards the heap base. 2 - While the upper material falls down filling the bucket, raise the arms gradually and at the same time retract the bucket to the end of its stroke.
Page 164 USING THE MACHINE AS A LOADER 3.12.2.2 LOADING OPERATIONS ON SLOPES DANGER • 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 lowered bucket. •...
Page 165 USING THE MACHINE AS AN EXCAVATOR 3.13 USING THE MACHINE AS AN EXCAVATOR DANGER • Use the machine as an excavator only after rotating the seat by 180° with respect to the correct driving position; for the specific procedure, see “3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERA- TIONS”.
Page 166 USING THE MACHINE AS AN EXCAVATOR 3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS DANGER • Before moving the equipment, make sure that no one is standing in the work area. • Before moving the equipment, make sure that the stabilizers are in the correct position. •...
Page 167 USING THE MACHINE AS AN EXCAVATOR 3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS IMPORTANT • Before moving the backhoe unit, make sure that the sliding guides are clean and lubricated with grease. 1 - Lower the stabilizers (1) to avoid overloading the rear wheels and to prevent the machine from oscillating. 2 - Swing the boom (2) against the machine.
Page 168 USING THE MACHINE AS AN EXCAVATOR 3.13.4 DIGGING METHOD DANGER • The geometry of the rotation fulcrum of the arms and the bucket make it possible to dig even beyond the stabilizer line, which makes the ground give way. Do not dig beyond the boom fulcrum line, since the ground may collapse and cause the machine to overturn.
Page 169 USING THE MACHINE AS AN EXCAVATOR 3.13.5 CHANGING THE BACKHOE BUCK- DANGER • When the coupling pins are removed or installed, chips may come off; always wear gloves, goggles and helmet. • The change of the equipment must be carried out by two persons, who must decide together the words and signals to use during operations.
Page 170 LONG PERIODS OF INACTIVITY 3.14 LONG PERIODS OF INACTIVITY 3.14.1 BEFORE THE PERIOD OF INACTIVITY DANGER • When draining the fuel, do not smoke or bring naked flames near the machine. Place a container under the machine to gather the fuel and prevent it from spreading around. If some fuel is spilt, clean the dirty surface immediately.
Page 171 LONG PERIODS OF INACTIVITY If the machine must be stored for a long period of inactivity, it is advisable to put it in a sheltered place and to take the following precautions, in order to keep all its components sound and efficient: 1 - Clean the machine thoroughly, repainting it where necessary in order to prevent oxidation.
Page 172 IMPORTANT • If the machine is stored without carrying out the monthly rust-prevention treatment, have maintenance performed by your Komatsu Utility Dealer. When using the machine after a long period of inactivity, proceed as follows: 1 - Remove the seals from the exhaust pipe and the fuel tank.
Page 173 TROUBLESHOOTING 3.15 TROUBLESHOOTING 3.15.1 HOW TO REMOVE THE MACHINE DANGER • When removing 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 figures on the right.
Page 174 TROUBLESHOOTING 3.15.3 IF THE BATTERY IS DEPLETED DANGER • When checking or carrying out any operation on the bat- tery, stop the engine and make sure that the ignition switch is in position « ». • The battery produces hydrogen, which may explode. Do not use naked flames and do not smoke near the battery, and avoid producing sparks.
Page 175 TROUBLESHOOTING 3.15.3.1 STARTING WITH BOOSTER CABLES DANGER • When starting the engine with the aid of another machine, connect the batteries in parallel. • When connecting the cables, avoid any contact between the positive cable (+) and the negative cable (-). •...
Page 176 (•): Always contact your Komatsu Utility Dealer when you have to carry out this operation. • : If the anomaly or its cause are not included in the failures indicated below, contact your Komatsu Utility Deal- er for the necessary repair.
Page 177 TROUBLESHOOTING 3.15.4.3 BRAKING SYSTEM TROUBLE CAUSE REMEDY • (•) Braking not regular for both wheels: Brake discs worn. Change. • (•) No oil in brake pump. Top up and bleed circuit. • (•) Air in braking circuit. Bleed circuit. • (•) Braking not regular on one side only: Air in braking circuit.
Page 178 TROUBLESHOOTING 3.15.4.5 ENGINE TROUBLE CAUSE REMEDY • • Oil pressure warning light remains on Oil level in oil pan too low. Top up. • • even with engine at high speed: Oil filter clogged. Change filter. • • Oil unsuitable for the season. Change.
Page 179 MAINTENANCE...
Page 180 • Carry out any operation on firm and level ground, after applying the parking brake. • Use Komatsu Utility genuine oils and greases; choose oils suitable for the ambient temperature. • Use clean oils and greases. Keep the oil and grease containers clean. Keep any foreign matter away from oils and greases.
Page 181 GUIDE TO MAINTENANCE • Never mix oils of different brands. Do not top up with any oil different from the oil used in the machine. If necessary, drain all the oil and fill the tank with the oil of the new brand. DANGER •...
Page 182 • Use only Komatsu Utility genuine spare parts. • Do not mix different types of oil. • Unless specified otherwise, the oils and the coolant used by Komatsu Utility to fill the tanks before the delivery of the machine are the following:...
Page 183 • The standards required for the use of permanent antifreeze are: SAE-J1034 and FEDERAL STANDARD O-A- 548D. In case of doubt regarding the applicable standard for the use of antifreeze, contact your Komatsu Utility Deal- er, who will supply you with exhaustive and precise information.
Page 184 • Do not remove or eliminate any electric component installed on the machine and do not install any electric com- ponent with characteristics different from those specified and approved by Komatsu Utility. • Be careful to keep the electric system dry.
Page 185 The parts subject to wear such as filters, bucket teeth, etc. must be replaced according to the periodic mainte- nance intervals prescribed or when they reach the wear limit. The timely change of these parts ensures an economic use of the machine. Use only Komatsu Utility genuine parts, which alone can guarantee excellent quality and interchangeability. ITEM CODE DESCRIPTION Q.ty...
Page 186 FUEL, COOLANT AND LUBRICANTS 4.3 FUEL, COOLANT AND LUBRICANTS PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE CAPACITY (l) AMBIENT TEMPERATURE RESERVOIR FLUID -30 -20 -10 50°C filling Change SAE 10W SAE 20W -20 Engine oil pan API CD SAE 30 SAE 40 Hydraulic system API CD...
Page 187 • Use engine oil with CD classification; if oil with CC classification is used, reduce the engine oil change interval by a half. • Use Komatsu Utility genuine products whose characteristics have been specifically formulated and approved for use in the engine, in the work equipment hydraulic circuit, in the transmission and in the axles and brakes.
Page 188 FUEL, COOLANT AND LUBRICANTS 4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin and therefore the use of the oils indicated in the following table is authorized and recommended : SUPPLIER HEES SYNTHETIC BIODEGRADABLE OIL KOMATSU...
Page 189 DRIVING TORQUES FOR SCREWS AND NUTS 4.4 DRIVING TORQUES FOR SCREWS AND NUTS 4.4.1 STANDARD DRIVING TORQUES Nm (Newton metre): 1 Nm = 0,102 kgm 10.9 Thread Pitch Spanner size diameter (mm) (mm) (mm) 0.96 ± 0.1 9.5 ± 1 1.3 ±...
Page 190 LUBRICATION 4.5 LUBRICATION 4.5.1 LUBRICATION DIAGRAM IMPORTANT • For the lubrication procedures for the single points, see “4.7 MAINTENANCE PLAN”. 2000 h 1000 h 500 h 250 h 50 h 10 h RWA28330 Engine oil Hydraulic oil Transmission oil Grease Brake oil...
Page 191 LUBRICATION 4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks) IMPORTANT • For the other greasing points, see “4.5.1 LUBRICATION DIAGRAM”. • The points indicated are symmetrical and must be lubricated every 10 hours. • The fork sliding bars and the safety pins must be lubricated with grease only to protect them from oxi- dation.
Page 192 LUBRICATION 4.5.3 LUBRICATION DIAGRAM (Front bucket rapid couplings) IMPORTANT • For the other greasing points, see “4.5.1 LUBRICATION DIAGRAM”. • The points indicated are symmetrical and must be lubricated every 10 hours. 10 h RWAA9200 Grease...
Page 193 LUBRICATION 4.5.4 LUBRICATION DIAGRAM (Telescopic arm) IMPORTANT • For the other greasing points, see “4.5.1 LUBRICATION DIAGRAM”. • Lubricate the telescopic arm guides only if the sliding shoes are made of brass. Plastic shoes do not require lubrication. 10 h RWA35390 Grease...
Page 194 LUBRICATION 4.5.5 LUBRICATION DIAGRAM (Offset device) IMPORTANT • For the other greasing points, see “4.5.1 LUBRICATION DIAGRAM”. 10 h RWA03080 Grease...
Page 195 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECT- ED WITH SAFETY To ensure safety at any moment while driving and using the machine, the operator must carry out all the periodic maintenance operations prescribed. Furthermore, the operator must periodically change the components indicat- ed in the table in the following page, which are especially related to safety and fire-prevention rules.
Page 196 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 4.6.1 CRITICAL PARTS FOR SAFETY FUEL SUPPLY SYSTEM Components related to safety that periodically need changing Q.ty Change interval Fuel pipe (Fuel tank - precleaner) Fuel pipe (Precleaner - fuel pump) Every 2 years or Fuel pipe (Fuel pump - fuel filter) 4000 hours, which- Fuel pipe (Fuel filter - injection pump)
Page 197 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY DELIVERY-RETURN HYDRAULIC SYSTEM Components related to safety that periodically need changing Q.ty Change interval Hydraulic pipe (Hydraulic pump - iron tube) Hydraulic pipe (Iron tube - backhoe distributor) Every 2 years or 4000 hours, which- Hydraulic pipe (Iron tube - loader distributor) ever occurs first...
Page 198 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY LOADER AND BACKHOE HYDRAULIC SYSTEM Components related to safety that periodically need changing Q.ty Change interval Hydraulic pipes (Cylinders - loader arm) Hydraulic pipes (Cylinders - loader bucket) Every 2 years or Hydraulic pipes (Cylinders - 4in1 bucket) 4000 hours, which- Hydraulic pipes (Cylinders - Backhoe boom)
Page 199 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY RWA31550 • For the serial numbers and the quantity of the components that periodically need changing, consult the spare parts catalogue section regarding the components connected with safety and the components that must be pe- riodically changed.
Page 200 MAINTENANCE PLAN 4.7 MAINTENANCE PLAN 4.7.1 WHEN REQUIRED PART OPERATION PAGE Engine air cleaner Check, clean or change Cab air filter Check and clean A/C recirculating air filter Check and clean (only for machines with air conditioner) Braking system Bleed Water separator Clean Front and rear wheels...
Page 201 MAINTENANCE PLAN 4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION PART OPERATION PAGE Joints Lubricate 4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic biodegradable oil type HEES is used) (Carry out these operations together with those to be performed every 50 HOURS, see “4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION”).
Page 202 MAINTENANCE PLAN 4.7.8 MAINTENANCE EVERY 250 HOURS OF OPERATION PART OPERATION PAGE Fan belt Check conditions and tension A/C compressor belt Check conditions and tension (only for machines with air conditioner) Battery Check electrolyte level Front axle Check levels (n. 3) Rear axle Check levels (n.
Page 203 MAINTENANCE PLAN 4.7.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION PART OPERATION PAGE Front axle Change oil Rear axle Change oil Hydraulic transmission Change oil Hydraulic transmission filter Change Engine valves Check clearance 4.7.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION PART OPERATION PAGE Hydraulic oil and suction filter...
Page 204 MAINTENANCE PLAN 4.7.1 WHEN REQUIRED 4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE DANGER • Remove the air cleaner only after stopping the engine and RPM x 100 electronic do not start the engine if the air cleaner is open. •...
Page 205 MAINTENANCE PLAN To change the safety cartridge (6), after removing the primary el- ement (3), proceed as follows: 1 - Remove the safety cartridge (6) and replace it with a new one. 2 - Once the safety cartridge (6) has been installed inside the fil- ter case (4), make sure that it is perfectly housed in its seat.
Page 206 MAINTENANCE PLAN 4.7.1.c CHECKING AND CLEANING THE RECIR- CULATING AIR FILTER (only for ma- chines with air conditioner) DANGER • Always wear safety goggles during the cleaning opera- tions. If the machine is provided with air conditioning system, besides the external filter (3) there is also an additional internal filter (6) RWAA11120 for the internal air recirculation.
Page 207 MAINTENANCE PLAN 4.7.1.d BLEEDING THE BRAKING CIRCUIT DANGER • The oil spilled on the floor may cause it to become slip- pery; immediately clean any dirty area. • Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of ac- cording to the anti-pollution regulations in force.
Page 208 MAINTENANCE PLAN 4.7.1.e CLEANING THE WATER SEPARATOR 1 - Loosen the screw (1) and drain the fuel contained in the wa- ter separator, gathering it in a container with suitable capaci- Use a 13 mm spanner. 2 - Loosen the central screw (2) and remove the bowl (3) and the filtering element (4).
Page 209 MAINTENANCE PLAN 4.7.1.g CHECKING AND ADJUSTING THE PARK- RWA28720 ING BRAKE IMPORTANT • During running-in, check the efficiency of the parking brake after the first 100 hours of operation. CHECK 11˚ 20' Check conditions • Tyre pressure in accordance with the prescribed values. •...
Page 210 4 - Accelerate until reaching the maximum speed. 5 - Press the brake pedals. The machine must brake smoothly on a straight line and the tension of the pedals must be con- stant. Otherwise, contact your Komatsu Utility Dealer. RWA35020...
Page 211 MAINTENANCE PLAN 4.7.1.j CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE This check must be carried out when operating on the braking unit in order to eliminate any trouble. To check and adjust the brake pedal stroke, proceed as follows: 1 - Insert the connection pin (1) in order to couple the pedals. 2 - By acting on the end-of-stroke rubber pads (2), position the pedals in correspondence with measure “A”...
Page 212 MAINTENANCE PLAN 4.7.1.l CHECKING AND ADJUSTING THE STA- BILIZER SLACK DANGER • When leaving the operator’s seat during the adjustment of the guides, remove the ignition key. 1 - Position the machine on level ground, raise the stabiizers completely, engage all the safety locks and stop the engine. 2 - Manually exert a thrust and traction force on each stabilizer RWA17250 and make sure that the slack between the mobile rod (1) and...
Page 213 MAINTENANCE PLAN 4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER The hydraulic oil used in the machines provided with demolition hammer deteriorates more quickly than the oil used in normal digging machines, therefore it is advisable to respect the following maintenance plan. 4.7.2.a CHANGING THE HYDRAULIC OIL FILTER In new machines, change the filter after the first 100÷150 hours...
Page 214 • Dirt, oil and fuel spread in the engine compartment near the hot areas may cause fires and damage the machine. Check if there are leakages frequently and carry out the necessary repairs immediately; if this occurs repeatedly, contact your Komatsu Utility Dealer. Before starting the engine, check: 1. if there are loose screws or nuts;...
Page 215 MAINTENANCE PLAN 4.7.3.c CHECKING THE FUEL LEVEL RWA02620 DANGER • When refuelling, avoid spilling fuel to prevent any risk of fire. If some fuel should inadvertently be spilled, clean the dirty area immediately. RPM x 100 • Fuel is flammable; neither use naked flames, nor smoke electronic while refuelling.
Page 216 MAINTENANCE PLAN 4.7.3.e CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL DANGER • The oil level must be checked with cold oil and the ma- chine positioned on level ground and in lubricating posi- tion. • If it is necessary to top up, stop the engine and eliminate the residual pressure from the equipment circuits (by moving the controls more than once) and from the tank RWA28690...
Page 217 MAINTENANCE PLAN 4.7.3.f DRAINING THE WATER SEPARATOR DANGER • The fuel is flammable; do not use naked flames and do not smoke while draining the water separator. • If some fuel is spilled, wipe it up immediately. This operation serves to drain the condensate water and must be carried out with full tank, in order to prevent air from entering the fuel supply circuit.
Page 218 MAINTENANCE PLAN 4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION 4.7.4.a LUBRICATING THE JOINTS IMPORTANT • Clean the grease nipples before applying the greasing pump. • After lubrication, remove all the contaminated grease that may have spread out of the nipples. •...
Page 219 MAINTENANCE PLAN BACKHOE RWA38060 10 25 10 11 12 13 10 - Boom swing cylinder base pin (4 points) 11 - Boom swing fulcrum pin (2 points) 12 - Boom swing cylinder head pin (2 points) 13 -Boom fulcrum pin (2 points) 14 - Lifting cylinder base pin (1 point)
Page 220 MAX. mark (see “4.3 FUEL, COOLANT AND LUBRICANTS”). IMPORTANT • Use new oil only. RWAA0250 • If constant and considerable leakages are observed, it is advisable to contact an Komatsu Utility Dealer to have the system checked and the necessary repairs carried out.
Page 221 MAINTENANCE PLAN 4.7.6.c LUBRICATING THE PROPELLER SHAFTS The lubrication must be carried out after carefully cleaning the grease nipples, by applying the greasing pump supplied together with the machine and using the prescribed grease. (See “4.3 FUEL, COOLANT AND LUBRICANTS”). Once the lubrication has been carried out, make sure that all the points have been lubricated and remove the contaminated grease that may have spread out of the joints.
Page 222 MAINTENANCE PLAN 4.7.6.d LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING AND THE REAR AXLE JOINTS The lubrication points (1) of the wheel joints are indicated in the figure and it is important to remember that they are located in symmetrical positions, while the central joint is lubricated by means of two grease nipples (2) positioned on the frame.
Page 223 • If there are signs of short circuit on the cables, find out the cause and repair them; always contact your Komatsu Utility Dealer for the troubleshooting. Make sure that there are no disconnected cables or signs of short circuit in the electrical system.
Page 224 • HYDRAULIC TRANSMISSION OIL FILTER CHANGE • ENGINE VALVE CLEARANCE CHECK AND ADJUSTMENT • HYDRAULIC OIL DRAIN FILTER CHANGE For details on the various maintenance operations, see the sections “EVERY 500 HOURS” and “EVERY 1000 HOURS”. For checks and adjustments, contact your Komatsu Utility Dealer.
Page 225 MAINTENANCE PLAN 4.7.8 MAINTENANCE EVERY 250 HOURS OF OPERATION Carry out the following operations together with those to be performed every 50 HOURS. 4.7.8.a ADJUSTING THE FAN BELT TENSION The fan belt can be reached after opening the engine hood (see “3.5.1 ENGINE HOOD”).
Page 226 MAINTENANCE PLAN 4.7.8.b ADJUSTING THE A/C COMPRESSOR BELT TENSION (Only for machines with air conditioner) DANGER • The coolant used in the air conditioning system is very dangerous. If it is sprayed into the eyes or in case of con- tact with the skin, it may cause blindness or frostbite.
Page 227 MAINTENANCE PLAN 4.7.8.c CHECKING THE BATTERY ELECTRO- LYTE LEVEL DANGER • Check the level with the machine parked on flat ground and raised loader arm with engaged safety lock. • Check the level only after stopping the engine and if nec- essary add distilled water only before starting work.
Page 228 MAINTENANCE PLAN 4.7.8.d CHECKING THE FRONT AXLE OIL LEV- DIFFERENTIAL This check is visual and serves to verify if the lubricant reaches the hole (1); if necessary, top up using the prescribed oil. (See “4.3 FUEL, COOLANT AND LUBRICANTS”). The level hole (1) must be used also as filling hole (use a 17 mm spanner).
Page 229 MAINTENANCE PLAN 4.7.8.f CHECKING THE HYDRAULIC TRANSMIS- SION OIL LEVEL MAX. DANGER MIN. • The level must be checked with running engine and trans- mission oil at operating temperature; be very careful, in order to avoid burns. • Let all the work equipment safety locks engaged, apply the parking brake and do not move the gearshift lever.
Page 230 MAINTENANCE PLAN 4.7.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the synthetic biodegradable oil type HEES is used) The following maintenance operation must be carried out after the first 500 hours of operation, together with the maintenance operations to be carried out “EVERY 500 HOURS”.
Page 231 MAINTENANCE PLAN 4.7.10 MAINTENANCE EVERY 500 HOURS OF OPERATION Carry out these operations together with those to be performed every 50 HOURS and every 250 HOURS. 4.7.10.a CHANGING THE ENGINE OIL DANGER • Change the oil with the machine parked on level ground and raised loader arm with engaged safety lock.
Page 232 MAINTENANCE PLAN 4.7.10.b CHANGING THE ENGINE OIL FILTER DANGER • Soon after the machine has been stopped the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40÷45°C before draining the oil.
Page 233 MAINTENANCE PLAN 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 removing the upper platform (1) with the relevant fastening screws (2). Use a 17 mm hexagon spanner.
Page 234 MAINTENANCE PLAN IMPORTANT Replacement interval • The hydraulic oil of the machines equipped with demoli- for element tion hammer deteriorates more rapidly than the oil of the machines used for simple digging operations. On new machines, change the filter after the first 100-150 hours of operation and for the successive changes keep to the indications given in the table beside.
Page 235 MAINTENANCE PLAN 4.7.10.d CHANGING THE FUEL FILTER DANGER • Change the filtering element after work, when the engine has cooled down to 40÷45°C. • When these operations are carried out, fuel may be spilled; clean the dirty areas immediately, in order to pre- vent any risk of slipping or fire.
Page 236 MAINTENANCE PLAN 4.7.10.e DRAINING THE FUEL TANK DANGER • When draining the fuel tank, avoid spilling fuel, since this may cause fires. • If some fuel is accidentally spilled, clean the dirty area im- mediately, in order to prevent it from getting slippery and to avoid fires.
Page 237 MAINTENANCE PLAN 4.7.10.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthet- ic biodegradable oil type HEES is used) DANGER • After stopping the engine, with the machine in the correct position for the performance of maintenance operations, eliminate the residual pressures from the equipment (by moving the controls more than once) and from the tank (by slowly loosening the filling cap).
Page 238 MAINTENANCE PLAN 4.7.10.g CLEANING THE OUTSIDE OF THE RADI- ATORS DANGER • If compressed air, steam or water are directed against a person, they may cause injuries. Always wear an eye shield and safety shoes. To clean the outside of the radiators it is first necessary to re- move the guard (1) positioned on the front of the engine hood.
Page 239 MAINTENANCE PLAN 4.7.10.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (Only for machines with air conditioner) DANGER • If compressed air, steam or water are directed against a person, they may cause injuries. Always wear an eye shield and safety shoes. The condenser (1) must be cleaned at the same at as the radia- RWAB0400 tors, see “4.7.10.g CLEANING THE OUTSIDE OF THE RADIA-...
Page 240 MAINTENANCE PLAN 4.7.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION Carry out these operations together with those to be performed every 50, 250, 500 HOURS. 4.7.11.a CHANGING THE FRONT AXLE OIL DANGER • Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of ac- cording to the anti-pollution regulations in force.
Page 241 MAINTENANCE PLAN 4.7.11.b CHANGING THE REAR AXLE OIL DANGER • Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of ac- cording to the anti-pollution regulations in force. This operation must be carried out with the machine positioned on level ground and at operating temperature, so that the oil be- comes fluid and can be easily drained, which facilitates the elim- RWAA9170...
Page 242 MAINTENANCE PLAN 4.7.11.c CHANGING THE HYDRAULIC TRANS- MISSION OIL DANGER • Carry out this operation with the machine parked on level ground and raised loader arm with engaged safety lock. • The hydraulic transmission oil must be drained at operat- ing temperature, which is very high, and may cause seri- ous burns;...
Page 243 8 - Put back the cover (1). 4.7.11.e CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE Since the check and adjustment of the engine valve clearance requires the use of special tools, have these oper- ations carried out by your Komatsu Utility Dealer.
Page 244 MAINTENANCE PLAN 4.7.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION Carry out these operations together with those to be performed every 50, 250, 500 and 1000 HOURS. 4.7.12.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FIL- CAUTION • On machines containing synthetic biodegradable hydrau- lic oil type HEES, carry out the change after the first 500 hours of operation and successively every 2000 hours, and in any case at least once a year.
Page 245 MAINTENANCE PLAN 8 - Raise the front mat and remove the cover (11). Use a 13 mm spanner 9 - Loosen the bleeder plug (12) positioned on the hydraulic pump, until no air bubbles can be observed in the oil that flows out (use a 3 mm setscrew spanner).
Page 246 MAINTENANCE PLAN IMPORTANT • The hydraulic oil of the machines equipped with demoli- Replacement interval tion hammer deteriorates more rapidly than the oil of the for hydraulic oil machines used for simple digging operations. Perform the oil changes according to the indications giv- 2000 en in the table beside.
Page 247 MAINTENANCE PLAN 1 - Remove the front guard (1) after removing the relevant fas- tening screws (2). 90˚ Use a 17 mm hexagon spanner. 2 - Open the engine hood (See “14.1 ENGINE HOOD”). 3 - Loosen and remove the upper cap (3) of the radiator. 4 - Open the radiator drain cock (4) (see Fig.
Page 248 For further details, see “3.3.1 FRONT INSTRUMENTS” pos. 17. 4.7.12.d CHECKING THE ALTERNATOR AND THE STARTER For any inspection and/or repair, contact your Komatsu Utility Dealer. If the engine is started frequently, have an inspection carried out every 1000 hours of operation.
Page 249 • The maintenance of the air conditioning system must be carried out exclusively by specialized person- nel. Specific equipment is required to check the coolant; have this maintenance operation carried out only by special- ized personnel and for this purpose contact your Komatsu Utility Dealer.
Page 250 • Have the dehydrating filter changed only by specialized personnel and for this purpose contact your Komatsu Utility Dealer. The filter (1) must be replaced every 4000 hours of operation or every 2 years, whichever occurs first.
Page 251 TECHNICAL SPECIFICATIONS...
Page 252 TECHNICAL DATA 5.1 TECHNICAL DATA 5.1.1 STANDARD OVERALL DIMENSIONS WITH CENTERED BACKHOE RWA26170 2150 2175 3035 2420 7360 5.1.2 STANDARD OVERALL DIMENSIONS WITH FOLDED BACKHOE RWA26180 2150 2175 1640 2420 5965...
Page 253 TECHNICAL DATA 5.1.3 TECHNICAL CHARACTERISTICS TOTAL MASS Minimum total mass ............kg 8000 Maximum total mass .
Page 254 TECHNICAL DATA 5.1.4 LIFTING CAPACITIES CAUTION • According to the harmonized standard EN474-5 (§ 4.1.7.5), the machine cannot lift weights exceeding 1000 kg, unless it is provided with appropriate equipment. • Carry out lifting operations only with the machine positioned on firm and flat ground. 5.1.4.1 SYMBOL TABLE 1850...
Page 255 TECHNICAL DATA 5.1.4.2 LIFTING CAPACITY (STANDARD BOOM) RWA26190 = 8000 Kg > 1000 Kg W= 600 mm = 160 Kg 20 MPa (200 Bar) 1850 -1 m -1 m -1 m...
Page 256 TECHNICAL DATA 5.1.4.3 LIFTING CAPACITY (OFFSET BOOM) RWA26200 = 8000 Kg > 1000 Kg W= 600 mm = 160 Kg 20 MPa (200 Bar) 1850 -1 m -1 m -1 m...
Page 257 AUTHORISED OPTIONAL EQUIPMENT...
Page 258 • Use exclusively optional or special equipment recommended and approved by Komatsu Utility and complying with the requisites indicated in the following tables. • Komatsu Utility cannot be held liable for any damage, accident, reduction of the machine efficiency due to the application and use of unauthorized equipment.
Page 259 FRONT EQUIPMENT QUICK COUPLING DEVICES 6.2 FRONT EQUIPMENT QUICK COUPLING DEVICES DANGER • The coupling and uncoupling operations must be per- formed on a firm and level surface. • The method described is valid for all the front equipment whose operation does not require the use of pressurized oil.
Page 260 FRONT EQUIPMENT QUICK COUPLING DEVICES 6.2.2 HYDRAULIC CONTROL QUICK COUPLING FOR STANDARD BUCK- The operations to be performed are those described in the previ- ous paragraph, with changes regarding the backward movement and the engagement of the fulcrum pins, which are obtained by means of the push buttons (8) and (9) located on the lever (2).
Page 261 4in1 BUCKET 6.3 4in1 BUCKET (For the characteristics, see “6.1 AUTHORIZED OPTIONAL EQUIPMENT”). 6.3.1 DESCRIPTION AND CONTROLS The 4in1 bucket can be used for several applications and elimi- nates the need to use specific equipment. Compared to the standard bucket, it comprises a mobile jaw (4) that can be opened to unload the material with no need to swing the bucket itself.
Page 262 4in1 BUCKET 6.3.3 INSTALLING THE 4in1 BUCKET DANGER • When the coupling pins are removed or installed, chips may come off; always wear gloves, safety goggles and helmet. • The change of the equipment must be carried out by two operators, who must decide together the words and sig- nals to be used during operations.
Page 263 4in1 BUCKET IMPORTANT • Before starting work, make sure that the bucket position indicator is correctly set (see “3.12.1 BUCKET POSITION INDICATOR”). 6.3.4 USING THE 4in1 BUCKET The 4in1 bucket can be used for the following applications: 1 - Loading (dumping the bucket as described in “3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL”).
Page 264 PALLET FORKS 6.4 PALLET FORKS (For the characteristics, see “6.1 AUTHORIZED OPTIONAL EQUIPMENT”). DANGER • Before lifting the load, make sure that the position of its centre (G) complies with the distances indicat- ed in the figure below. Furthermore, the load must always be centered with respect to the forks. Non- compliance with these rules may cause serious damage and even death.
Page 265 PALLET FORKS 6.4.3 USING THE FORKS DANGER • Before working with the forks, the operator must evaluate the increased dimensions of the machine and learn how to use the fork controls. • The forks protrude beyond the bucket outline and there- fore it is necessary to be very careful when manoeuvring the machine, especially in reduced spaces.
Page 266 PALLET FORKS 6.4.3.2 OVERTURNING THE FORKS FOR TRAV- EL ON ROADS 1 - Remove the safety pins (4) and the pins (3). 2 - Make the forks slide towards the centre of the bucket, over- turn them and insert them in the supports (5). 3 - Install the pins (3) and the safety pins (4).
Page 267 PALLET FORKS 6.4.4 REMOVING THE FORKS DANGER • When removing the forks, the supports and the bar, be very careful, in order not to cut or crush your hands or feet. 1 - Manoeuvre the lifting arm and swing the bucket until resting the forks (1) on the ground in horizontal position. 2 - Remove the safety pins (6) and the pins (7).
Page 268 BACKHOE TELESCOPIC ARM 6.5 BACKHOE TELESCOPIC ARM 6.5.1 DESCRIPTION AND CONTROL This configuration of the backhoe arm makes it possible to work with the equipment installed at a variable distance longer than the distance available with the standard arm. With the application of this arm (and with extended arm), the breakout force at the bucket pin is reduced and only lighter loads can be handled;...
Page 269 BACKHOE TELESCOPIC ARM 6.5.2 SAFETY DEVICES RWAB0470 The telescopic arm is equipped with a safety pin (6) that locks the sliding arm (2) when it is completely retracted and prevents any accidental extension of the same. The safety pin (6), held in its seat by the retainer (7), must be in- serted and prevent the extension of the arm as shown in Fig.
Page 270 BACKHOE TELESCOPIC ARM 6.5.4 MAINTENANCE The telescopic arm requires two maintenance operations: 1 - Lubrication of the joints (see “4.5.4 LUBRICATION DIAGRAM”). 2 - Adjustment of the slide guide (8) slack, which must be carried out occasionally, when impacts or vibrations are noticed during work.
Page 271 BACKHOE TELESCOPIC ARM CAUTION • If the adjusting dowels (9) protrude to the same extent on the two sides, the operation described at point 6 can be carried out either on the right or left side. 6 - Loosen the four lock nuts (10) and tighten the adjusting dow- els (9) thoroughly, until taking up the slack completely.
Page 272 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 6.6 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLI- TION HAMMER DANGER • For the characteristics of the hammer, see “6.1 AUTHORIZED OPTIONAL EQUIPMENT”. • The demolition hammer is very noisy, therefore always wear headphones when using it. 6.6.1 DESCRIPTION AND CONTROL The machine can be fitted for the application of a demolition hammer on the backhoe;...
Page 273 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 6.6.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED The choice of the suitable tool is a very important factor to obtain the maximum productivity from the demolition hammer. The shape and size of the tool must be defined according to the nature of the material to be broken and to the type of work to be carried out.
Page 274 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 4 - To facilitate the sliding of the tool on its seat, check the thrust direction and always correct the hitting position of the ham- mer by means of the bucket and arm control. RWA38520 5 - Always make sure that the arm thrust is optimal, in order to avoid harmful and useless strokes.
Page 275 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER ALWAYS AVOID THE FOLLOWING INCORRECT USES: 1 - Gathering or moving stones with the demolition hammer. RWA06460 2 - Rotating the upper structure while using the hammer. RWA38530 3 - Moving the tool while it is hitting the material to be broken. RWA06480 4 - Working with the hammer in horizontal position or even with greater inclination.
Page 276 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 5 - Levering with the tool after driving it into the material to be broken. RWA06500 6 - Hitting the ground with the hammer bit. RWA38540 7 - Lifting the machine by levering on the hammer bit with the bucket cylinder completely extended.
Page 277 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 6.6.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER 6.6.3.1 INSTALLING THE HAMMER DANGER • The machine must be parked on flat ground, with the front equipment resting on the ground. • For the installation, the hammer must be positioned hori- zontally, with the end directed towards the machine.
Page 278 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 3 - Remove the plugs of the machine pipes and of the hammer STANDARD flexible pipes. Use 32, 36, 38 and 41 mm hexagon spanners. 4 - Connect the right pipe to the coupling (1) and the left pipe to the coupling (2), making sure that the sizes of the pipe fittings are as required.
Page 279 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER 6.6.3.2 REMOVING THE HAMMER To remove the hammer, proceed as follows: 1 - Stop the engine and move the hydraulic controls in all directions, in order to completely release the residual pressures present in the circuits of the machine. 2 - Press the hammer control pedal to release the pressure present in the hammer delivery pipe.
Page 280 APPLICATION OF THE OFFSET DEVICE 6.7 APPLICATION OF THE OFFSET DEVICE DANGER • When it is necessary to move the machine or travel on roads, the offset device must be positioned cen- trally with respect to the boom axis. • To carry out digging operations on vertical walls, the fulcrum pin (1) of the revolving support (2) must be perfectly vertical;...
Page 281 APPLICATION OF THE OFFSET DEVICE 6.7.1.2 VERSION WITH SERVO CONTROLS (if installed) If the machine is equipped with backhoe servo controls, the movement of the equipment with offset device is obtained by means of the push buttons (7) and (8) positioned on the left joy- stick lever.
Page 282 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW 6.8 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW DANGER • Some equipment that can be installed instead of the standard bucket make the machine unsuitable for travelling on roads.
Page 283 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW 6.8.2 INSTALLING AND CONNECTING THE EQUIPMENT The equipment must be installed following the procedure indicat- ed in paragraph “3.13.5 CHANGING THE BACKHOE BUCKET”. Connect the delivery and return pipes by proceeding as follows: 1 - After connecting the equipment, stop the engine and shift the hydraulic controls in all directions, in order to release the re- sidual pressure from the machine circuits.
Page 284 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET 6.9 ARRANGEMENT FOR THE INSTALLATION OF THE CLAM- SHELL BUCKET 6.9.1 DESCRIPTION AND CONTROL DANGER • The machine equipped with the revolving clamshell bucket cannot travel on roads. • The installation of the clamshell bucket must be carried out at the work site; if the machine must travel on roads, remove the bucket.
Page 285 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET 6.9.1.2 VERSION WITH SERVO CONTROLS (if installed) If the machine is equipped with backhoe servo controls, the swinging movements of the clamshell bucket are operated through the push buttons (2) and (3) positioned on the left joy- stick lever.
Page 286 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET 6.9.2 INSTALLING THE CLAMSHELL BUCKET DANGER • The machine must be parked on flat ground, with the front equipment resting on the ground. • When the coupling pins are removed or installed, chips may come off;...
Page 287 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET CAUTION • During the following steps, take care to prevent any impu- rities from getting into the pipes and the cylinder. FOR STANDARD ARM (FIG. A) 6 - Disconnect the pipes (2-3) that operate the piston from the bucket cylinder (1) and seal the cylinder couplings (4).
Page 288 ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER 6.10 ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER DANGER • The manual hydraulic hammer is very noisy; always wear headphones when using it.. • The manual hydraulic hammer transmits intense vibrations that may cause psychical and physical stress to the operator;...
Page 289 ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER 6.10.2 CONNECTING AND REMOVING THE HAMMER DANGER • The connection and removal of the hammer must be car- ried out with the machine parked and the equipment rest- ing on the ground, the parking brake applied and the control lever safety locks engaged.
Page 290 ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER 3 - Turn the ignition key to position « » and press the hammer control push button (4) to release the residual pres- sure from the hammer delivery pipe; after releasing the pressure, press the push button (4) again to discon- nect the circuit.
Page 291 LOAD STABILIZER SYSTEM 6.11 LOAD STABILIZER SYSTEM (LSS) (Optional) CAUTION • Never operate the load stabilizer system while using the backhoe. The load stabilizer system (LSS) improves the performance of the machine during travel, regardless of the type of terrain and of the bucket load. It reduces the oscillations while travelling and while carrying loads, at the same time increasing productivity and the operator’s comfort.
Page 292 REAR EQUIPMENT RAPID COUPLING DEVICE 6.12 REAR EQUIPMENT RAPID COU- PLING DEVICE DANGER • The work equipment coupling and uncoupling operations must be carried out on a firm and level surface. • The method described is valid for any rear equipment whose operation does not require the use of pressurized oil.
Page 293 REAR EQUIPMENT RAPID COUPLING DEVICE 6.12.1 EQUIPMENT COUPLING AND RE- RWA38570 LEASE PROCEDURE DANGER • During the installation or removal of the coupling pins, chips may come off; always wear safety gloves, goggles and helment during these operations. • To change the equipment the operator must seek the aid of another person;...
Page 294 REAR EQUIPMENT RAPID COUPLING DEVICE • Release procedure: 1 - Remove the safety pin (5) after removing the relevant retainer (6). 2 - Slightly raise the bucket from the ground and insert the release lever (9) in the apposite hole in the rapid coupling (1). 3 - Exert a downward pressure with the release lever (9), until the coupling pin (3) disengages from its seat.
Page 295 REAR EQUIPMENT RAPID COUPLING DEVICE 6.12.2 MAINTENANCE For the various maintenance operations and for the checks to be carried out on the equipment rapid coupling de- vice, see the specific manual provided.
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