KOMATSU WB150AWS-2N BACKHOE LOADER OPERATION & MAINTENANCE MANUAL (SN:A90002 & UP) KOMATSU WB150AWS-

CEAM013002

Operation & Maintenance Manual

WB150AWS-2N BACKHOE LOADER

SERIAL NUMBERS

WB150-2N

A90002

and UP

This material is proprietary to Komatsu Utility Division and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Utility Division.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

December 2004

Copyright 2004 Komatsu Published in USA Komatsu America Corp.

PRODUCT PUBLICATIONS INFORMATION Various product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals.

Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages.

The Publications listed below are available for this particular machine(s).

DESCRIPTION

FORM NUMBER

PARTS BOOK - PAPER: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB040901

OPERATION AND MAINTENANCE MANUAL: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM013002

SHOP MANUAL Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM021900 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEBM4D9801

SAFETY MANUAL Machine Specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BL02-08

Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America Corp. Extranet Literature Ordering System.

If the Extranet Literature Ordering System is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax orders.

PUB INFO PAGE.fm

12/3/04

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM AND RETURN TO

DataKom Publications and Training Division 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887

COMPANY NAME PURCHASE ORDER NO.

SHIP TO ATTN.

TYPE or PRINT ONLY

STREET ADDRESS

ORDER DATE

CITY, STATE, ZIP CODE COUNTRY

PHONE NO.

FAX NO.

SHIPPING METHOD

DISTR/BRANCH CODE

IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. QTY.

PUBLICATION FORM NO.

➥

PARTS BOOK P-Paper M-Microfiche

KDC91E 071403

PUBLICATION DESCRIPTION

MODEL NUMBER

CURRENT PRICES WILL BE CHARGED

SERIAL NUMBER

EMISSION CONTROL WARRANTY EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY) 1.

Products Warranted Komatsu America International Company, Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collectively “Komatsu”) produce and/or market products under brand names of Komatsu, Dresser, Dressta, Haulpak and Galion. This emissions warranty applies to new engines bearing the Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to these engines produced on or after January 1, 2000. This warranty will be administered by Komatsu distribution in Canada.

2.

Coverage Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform, at the time of sale by Komatsu, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as measured from the date of delivery of the engine to the ultimate purchaser.

3.

Limitations Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. Komatsu is not responsible for failures or damage resulting from what Komatsu determines to be abuse or neglect, including, but not limited to: operation without adequate coolant or lubricants; over fueling; over speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water, dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs, “downtime” expense, related damage, fines, all business costs or other losses resulting from a warrantable failure.

KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT): 1.

Produits garantis: Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/ou font la mise en marché de produits portant les noms de marque Komatsu, Dresser, Dressta, Haulpak et Galion. Cette garantie sur les émissions s’applique à tous les nouveaux moteurs portant le nom Komatsu, installés dans ces produits et utilisés au Canada dans des machines conçues pour utilisation industrielle nonroutière. Cette garantie s’applique seulement sur les moteurs produits à partir du 1er Janvier 2000. Cette garantie sera administrée par la distribution de Komatsu au Canada .

2.

Couverture: Komatsu garantit à l’acheteur ultime et chaque acheteur subséquent que le moteur est conçu, construit et équipé en toute conformité, au moment de la vente par Komatsu, avec toutes les Réglementations fédérales américaines sur les émissions applicables au moment de la fabrication et qu’il est exempt de défauts de construction ou de matériaux qui auraient pour effet de contrevenir à ces réglementations en dedans de 5 ans ou 3000 heures d’opération, mesuré à partir de la date de livraison du moteur au client ultime.

3.

Limitations: Les bris, autres que ceux résultant de défauts de matériaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu n’est pas responsable pour bris ou dommages résultant de ce que Komatsu détermine comme étant de l’abus ou négligence, incluant mais ne se limitant pas à: l’opération sans lubrifiants ou agent refroidissants adéquats; la suralimentation d’essence; la survitesse; le manque d’entretien des systèmes de lubrification, de refroidissement ou d’entrée; de pratiques non-propices d’entreposage, de mise en marche, de réchauffement, de conditionnement ou d’arrêt; les modifications non-autorisées du moteur. De plus, Komatsu n’est pas responsable de bris causés par de l’essence inadéquate ou de l’eau, des saletés ou autres contaminants dans l’essence. Komatsu n’est pas responsable des réparations non-reliées au moteur, des dépenses encourues suite aux temps d’arrêts, des dommages relatifs, amendes, et de tout autre coût d’affaires ou autres pertes résultant d’un bris couvert par la garantie.

KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSÉQUENTS. Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL N’Y A AUCUNE AUTRE GARANTIE, EXPRESSE OU SOUS -ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIÈRE.

CEKQ000600 - Komatsu America International Company 12/99

DEG. BTDC

RÉGLAGE DE L’ALLUMAGE INJECTION INITIALE

VITESSE STATIQUE

PORTÉE DE VALVE À FROID (mm)

IN.

HP)

ENGINE DATAPLATE - ENGLISH / FRENCH

KOMATSU LTÉE FABRIQUÉ AU JAPON

KOMATSU LTD. MADE IN JAPAN

DEG. BTDC DATE OF MANUFACTURE

RPM FAMILY EMISSION LIMIT

EX. FUEL RATE AT ADV.

Kw (

_____________________________________________

INITIAL INJECTION TIMING

IDLE SPEED

VALVE LASH COLD (mm)

ADV. LOAD OUTPUT

FIRING ORDER

EXHAUST EMISSION CONTROL SYSTEM

CHARGE DE SORTIE ADV.

DISPLACEMENT

ENGINE FAMILY

SYSTÈME DE CONTROLE DES ÉMISSIONS D’ÉCHAPPEMENT

SERIAL NO.

ENGINE MODEL

FAMILLE DU MOTEUR

MODÈLE DU MOTEUR

RPM mm3/STROKE

1-5-3-6-2-4

LITERS

DATE DE FABRICATION

LIMITE D’ÉMISSION DE LA FAMILLE

TAUX D’ESSENCE À ADV.

mm3/BATTEMENT

SÉQUENCE DE MISE À FEU

LITRES

DÉPLACEMENT

NO. SÉRIE

AVERTISSEMENT DES BLESSURES PEUVENT RÉSULTER ET LA GARANTIE S’ANNULER SI LES RPM DU TAUX D’ESSENCE OU L’ALTITUDE EXCÈDENT LES VALEURS MAXIMALES PUBLIÉES POUR CE MODÈLE ET SON APPLICATION.

IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTIFIED TO OPERATE ON DIESEL FUEL. WARNING INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL RATE RPM OR ALTITUDES EXCEED PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION.

INFORMATION IMPORTANTE SUR LE MOTEUR CE MOTEUR EST CONFORME AUX NORMES AMÉRICAINES DEL’EPA (ANNÉE DU MODÈLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNITION PAR COMPRESSION. CE MOTEUR EST CERTIFIÉ POUR OPERATION À ESSENCE DIÉSEL.

INTRODUCTION

WB150AWS-2N

0

0-1

INTRODUCTION

FOREWORD This manual contains all the necessary information on the machine and the safety regulations related to it, together with the use and maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time.

This manual, together with the parts book, is an integral part of the machine and must accompany it, even when it is resold, until its final disposal.

The manual must be handled with the greatest care and always kept with the machine, so that it can be consulted at any moment; it must be placed in the appropriate compartment behind the seat, where also the ownership documents and the logbook are usually kept.

This manual must be given to the persons who have to use the machine and carry out the routine maintenance operations; they must read the contents carefully more than once, in such a way as to clearly understand what are the correct operating conditions and the dangerous conditions that must be avoided. In case of loss or damage, request a new copy from your distributor.

The illustrations contained in this manual may represent machine configurations available upon request. These machines are constantly improved in order to increase their efficiency and reliability; this manual sums up all the information regarding the most recent techniques applied at the moment in which the machine is marketed. For any further and/or updated information, contact your distributor.

For the various maintenance phases it is advisable to consult the hour meter and in particular the maintenance plan set on the electronic unit of the machine frequently. The display of the maintenance plan can be obtained by means of an appropriate screen positioned on the upper part of the front dashboard. In any case, the maintenance plan can be also consulted on the relevant manual provided. Keep to the various maintenance intervals indicated on the screen and on the use and maintenance manual.

Over the years your distributor have gathered considerable experience in customer service. If more information is needed, do not hesitate to contact your distributor, he always knows how to get the best performance from the machine, he can suggest the use of the equipment that is most suitable for specific needs and can provide the technical assistance necessary for any change that may be required to conform the machine to the safety standards and traffic rules. Furthermore, your distributor also ensure their assistance for the supply of Komatsu genuine spare parts, which alone guarantee safety and interchangeability.

The table included in this manual must be filled in with the machine data, which are the data that must always be indicated to the distributor when requiring assistance and ordering spare parts

Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operators and maintenance personnel must read this manual thoroughly before operating or maintaining this machine. This manual should be kept near or with the machine for reference and periodically reviewed by all personnel who operate it.

Some actions involved in operation and maintenance can cause a serious accident, if they are not performed in the manner described in this manual. The procedures and precautions given in this manual apply only to the intended uses of this machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual.

KOMATSU delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety features and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your local distributor or KOMATSU before operating the machine. The safety description is given in SAFETY INFORMATION and in the SAFETY section 1.

0-2

WB150AWS-2N

INTRODUCTION

SAFETY INFORMATION Most accidents are caused by failure to follow fundamental safety rules for the operation and maintenance of the machine. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing maintenance and machine operations.

To identify safety messages in this manual and on machine product graphics, the following signal words are used: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to most extreme situations.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

Remark This word is used for precautions that must be taken to avoid actions, which could shorten the life or damage the machine.

The safety precautions are described in the SAFETY section 1.

KOMATSU cannot predict every circumstance that might involve a potential hazard in operation and maintenance.

Therefore the safety message in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine or causing injury. If you are unsure about the safety of some procedures, contact your local distributor.

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INTRODUCTION

APPROVED AND NON APPROVED USES The BACKHOE LOADERS described in this manual have been designed and constructed to be used mainly for the following functions, any non-approved used may void the warranty, damage the machine or possibly injure the operator.

APPROVED ★ LOADING, SCRAPING OR GRADING OPERATIONS. ★ EXCAVATING. Installation of optional equipment can also be used in the following applications, use only KOMATSU approved equipment. ★ HANDLING OF MATERIALS (MP BUCKET - PALLET FORKS). ★ SNOWPLOWING (ANGLE DOZER BLADE - SNOWPLOW). ★ DEMOLITION (HAND HAMMER OR HAMMER ON BACKHOE UNIT). ★ DITCH CLEANING AND DIGGING (SPECIAL BUCKETS).

NON APPROVED This paragraph describes some of the improper or unauthorized uses of the machine; since it is impossible to predict all the possible improper uses, if the machine happens to be used for any particular application other than those approved above, it is important to contact your dealer before carrying out the work operations. ★ USE OF MACHINE FOR LIFTING OR TRANSPORTING PERSONNEL IN ANY MANNER. ★ TRANSPORTATION OF FLAMMABLE LIQUIDS. ★ LIFTING, MOVING OR TRANSPORTING OTHER MACHINES WITH THE FRONT END LOADER OR BACKHOE UNIT. ★ TOWING OTHER EQUIPMENT WITH THE TRACTOR UNIT OR WORK EQUIPMENT. ★ USING THE BACKHOE UNIT TO MOVE OR REPOSITION THE MACHINE. ★ USING THE BACKHOE OR LOADER AS A HAMMER OR FOR STRIKING OR DRIVING OBJECTS. ★ TOWING THE MACHINE AT HIGH SPEEDS ★ TRAVELING AT HIGH SPEEDS.

0-4

WB150AWS-2N

INTRODUCTION

PRODUCT INFORMATION Listed are features and machine identification locations. The backhoe loader and main components are identified by serial numbers stamped on identification plates or decals attached to the machine or component.

MAIN FEATURES ★ Simple and easy operation. ★ Power assisted steering with priority hydraulic system. ★ Loader control through a single lever ensures combined movements that can be modulated proportionally and continually. ★ Joystick backhoe controls with two levers ensure combined movements that can be modulated proportionally and continually. ★ Complete series of instruments visible from the two operating positions, loader or backhoe. ★ Separate engine throttle controls for the two operating positions. ★ Foot brake control. ★ Easy maintenance with simplified intervals.

BREAK IN PERIOD Every new machine is properly adjusted and tested before delivery. A new machine must be operated carefully for the first 100 hours in order to ensure proper run in time for the various components. It the machine is subjected to excessive or severe work loads at the beginning of it’s operation, it’s functions will be greatly reduced or damaged.

Every new machine must be used carefully, pay special attention to the following indications: ★ After start up, let the engine idle at a low RPM for 5 minutes, to warm it up the machine gradually before beginning actual operation. ★ Operate the machine with limited loads. Avoid abrupt starts, accelerations, sudden decelerations, abrupt reversals or sudden stops. ★ After the first 250 hours, carry out the following maintenance, in addition to normal maintenance performed at 250 hours perform: A. Change the hydraulic transmission oil and filter.

B. Change the differential unit oil, front and rear axle.

C. Change the oil in the final reduction gears, front and rear axle.

D. Check and adjust the engine valve clearance.

E. Change the hydraulic system oil filter. SYNTHETIC BIODEGRADABLE OIL TYPES SYNTHETIC BIODEGRADABLE OIL TYPES On machines in which synthetic biodegradable types of oils are used, the following operations are to be performed besides the standard maintenance operations: ★ After the first 50 hours of operation, change the hydraulic system filter. ★ After the first 500 hours of operation, change the hydraulic system oil and filter.

WB150AWS-2N

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INTRODUCTION

PRODUCT IDENTIFICATION The serial numbers and model numbers on the components are the only numbers that your distributor will need when requiring assistance or ordering replacement parts. It is a good idea to record this information in this manual on page 0-9 (Serial Number and Distributor Information). All views indicated below are viewed from the operators position.

MACHINE SERIAL NUMBER The machine serial number is stamped on the right side of the front part of the main tractor frame.

MACHINE IDENTIFICATION PLATE The Komatsu backhoe loaders described in this manual are provided with the CE mark which certifies that they are in compliance with the CE standards.

The identification plate is located inside the operators cab on the left vertical wall of the frame, behind the brake pedals.

ENGINE SERIAL NUMBER AND EMISSION LABEL The engine serial number is stamped on a plate located on top of the engine valve cover.

The emission label is located on the right side of the valve cover.

0-6

WB150AWS-2N

INTRODUCTION The engine serial number is stamped on the plate positioned on the rear side of the tappet cover.

The plate regarding the exhaust emission regulations is applied to the front side of the tappet cover.

FRONT AXLE SERIAL NUMBER The serial number for the front axle is stamped on a plate located on the right side of the axle housing.

REAR AXLE SERIAL NUMBER The serial number for the rear axle is stamped on a plate located on the left side of the axle housing.

WB150AWS-2N

0-7

INTRODUCTION TRANSMISSION SERIAL NUMBER The serial number for the transmission is stamped on a plate located on the right side of the transmission case.

CAB SERIAL NUMBER The serial number for the cab is stamped on a plate located on the right center pillar.

CANOPY SERIAL NUMBER The serial number for the canopy is stamped on the plate located on the inside upper right corner.

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INTRODUCTION

SERIAL NUMBERS AND DISTRIBUTOR INFORMATION MODEL: WB150AWS-2N

Machine # Engine # Front axle # Rear axle # Transmission # Cab or Canopy #

Distributor:

Address:

Phone # Contacts:

NOTES:

WB150AWS-2N

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INTRODUCTION

CONTENTS INTRODUCTION FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 APPROVED AND NON APPROVED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 NON APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 PRODUCT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 MAIN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 SYNTHETIC BIODEGRADABLE OIL TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 MACHINE IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 ENGINE SERIAL NUMBER AND EMISSION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 FRONT AXLE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7 REAR AXLE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7 TRANSMISSION SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 CAB SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 CANOPY SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 SERIAL NUMBERS AND DISTRIBUTOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9 CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10

SAFETY SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCATION OF THE SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCATION OF THE PICTOGRAM DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 DECALS DEFINED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 LEAVING OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 CHECKING THE REAR VIEW MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 FIRE PREVENTION FOR FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 PREVENTING BURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 DUST HAZARD PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 CRUSH OR PINCH POINT DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 FIRE EXTINGUISHER AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 INSIDE OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

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INTRODUCTION PRECAUTIONS WHEN USING ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 PRECAUTIONS FOR ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 PRECAUTIONS BEFORE STARTING WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 PRE OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 PERFORM A WALK AROUND CHECK OF YOUR MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 UNDER THE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 IN THE OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 START UP CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 ROOM VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 WORK SITE HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 WORKING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 RULES FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31 RULES FOR TRAVELING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 TRAVELING ON ICY/SNOW COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 WORKING ON LOOSE OR UNSTABLE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 VISIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 TRAVEL POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 TRAVELING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 BUCKET PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 PARKING ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 PARKING FOR LONG PERIODS OF TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37 PARKING ON AN INCLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37 SAFETY LOCK USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38 LOADER CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39 BACKHOE LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 LOADING AND SECURING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 EMERGENCY RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43 MOVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43 PRECAUTIONS DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 WARNING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 EQUIPMENT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 USING DROP LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 ENGINE OPERATING DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 RULES FOR REFUELING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 COOLING SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46 USING LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

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INTRODUCTION ELECTRICAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46 CONNECTING CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47 DISCONNECTING CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48 PRECAUTIONS CONCERNING THE GEARSHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48 HIGH PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49 HIGH TEMPERATURES AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49 ROTATING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49 DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50 INFLATING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50 EXHAUST SYSTEM PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51 HEES OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51 CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52 VIBRATIONS TO WHICH OPERATOR IS EXPOSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

OPERATION GENERAL VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 FRONT VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 REAR VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 VIEW OF MACHINE CONTROLS - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 VIEW OF MACHINE CONTROLS - PPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 MACHINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 TRANSMISSION LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 MAIN FUNCTIONS OF THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 SAFETY CODE PUSH BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 DIM PUSH BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 4WD PUSH BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 GEAR SHIFTING WITH SEMIAUTOMATIC LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 ACCIDENTAL PREVENTION SELECTION DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 AUTOMATIC LOGIC PUSH BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 GEAR SHIFTING WITH AUTOMATIC LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 FWD/REV REVERSAL WITH LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 KICK DOWN FUNCTION FOR 1ST AND 2ND GEAR ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 DECLUTCH FUNCTION FOR THE 1ST AND 2ND GEAR ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 DIAGNOSTIC FUNCTION FOR MACHINES NOT WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 DIAGNOSTIC FUNCTION FOR MACHINES WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 FRONT INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 TRANSMISSION OIL TEMPERATURE ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 ENGINE COOLANT TEMPERATURE ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

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INTRODUCTION FOUR WHEEL DRIVE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 LOW FUEL ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 DIRECTIONAL SIGNAL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 HIGH BEAM INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 PARKING BRAKE LOW BRAKE FLUID ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 OPTIONAL EQUIPMENT ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 MULTIFUNCTIONAL SWITCH LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 FOUR WHEEL DRIVE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 WINDSHIELD WIPER/WASHER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 FRONT WORK LAMPS SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 EMERGENCY HAZARD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 ELECTRIC SAFETY VALVE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 STEERING CONTROL PUSH BUTTON UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 ELECTRONIC DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 BRAKE PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 LOADER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 KICK DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 HAND THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 SIDE INSTRUMENTS AND CONTROLS - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 FUEL LEVEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 TACHOMETER AND HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 ENGINE COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 AIR CLEANER RESTRICTION ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 ENGINE OIL PRESSURE ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 PREHEAT INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 ALTERNATOR ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 ENGINE COOLANT TEMPERATURE ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 OPTIONAL EQUIPMENT ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 AUDIBLE WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 REAR WORK LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 REAR WINDSHIELD WIPER/WASHER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 EMERGENCY FLASHING LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 REAR HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 LOAD STABILIZER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 AIR CONDITIONING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 BLOWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 BACKHOE POWER CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 BACKHOE BOOM LOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 OPTIONAL SWITCH LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 SIDE INSTRUMENTS AND CONTROLS - PPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

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INTRODUCTION FUEL LEVEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 TACHOMETER AND HOUR METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 ENGINE COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 AIR CLEANER RESTRICTION ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 ENGINE OIL PRESSURE ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 PREHEAT INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 ALTERNATOR ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 ENGINE COOLANT TEMPERATURE ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 OPTIONAL EQUIPMENT ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 AUDIBLE WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 REAR WORK LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 REAR WINDSHIELD WIPER/WASHER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 EMERGENCY FLASHING LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 REAR HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 LOAD STABILIZER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 AIR CONDITIONING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 BLOWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 BACKHOE CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 BACKHOE BOOM LOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 LOCK OUT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 LEFT OUTRIGGER CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 RIGHT OUTRIGGER CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 LOADER LEVER BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 LOADER SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 DECLUTCH PUSH BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 BUCKET OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 FRONT OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 BUCKET CLOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 FRONT OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 BACKHOE CONTROLS - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 ISO CONTROLS - EXCAVATOR STYLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 OPT CONTROLS - BACKHOE STYLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 STABILIZER CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 BACKHOE CONTROLS - PPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 PPC LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 OUTRIGGER SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 ISO CONTROLS - EXCAVATOR sTYLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 OPT CONTROLS - BACKHOE STYLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 JOYSTICK LOCK LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 SUPPORT ADJUSTING KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 JOYSTICK STROKE ADJUSTING KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

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INTRODUCTION TELESCOPIC ARM BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 HAMMER BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 PATTERN CHANGE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 OFFSET BOOM LEFT BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 BACKHOE BOOM LOCK CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 STEERING WHEEL LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 OVERHEAD LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 ELECTRIC OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 12V SUPPLY OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 BATTERY DISCONNECTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 FUSES AND RELAYS - A90002 TO A90008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 EQUIPMENT FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 ENGINE FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64 SIDE INSTRUMENT PANEL RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 FUSES AND RELAYS - A90009 AND UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 EQUIPMENT FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 ENGINE FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 SIDE DASHBOARD - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 SIDE DASHBOARD - PPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 OPERATOR’S COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 SIDE WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 ENTRY DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 OPERATOR ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75 SAFETY SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 DRIVER’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 SAFETY EQUIPMENT AND STORAGE AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 DOCUMENT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 TOOL CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79 CHECKS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79 VISUAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79 DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79 OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 CHECKING THE FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

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INTRODUCTION STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 TEMPERATE CLIMATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 WARMING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 HEATING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83 MOVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83 ENGAGING THE FOUR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84 WORKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85 MAXIMUM IMMERSION DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87 PARKING ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87 PARKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91 LOADING AND UNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91 TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 COLD SEASON PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93 FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94 OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94 END OF WORK PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94 WARM SEASON PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95 OPERATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96 BUCKET POSITION INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96 ORGANIZING THE WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96 LOADING HEAPED AND LEVEL MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97 LOADING OPERATIONS ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97 CHANGING THE GP BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98 USING THE BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98 BUCKET POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 POSITION FOR DIGGING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 DIGGING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 CHANGING THE BACKHOE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101 OFF SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103 BEFORE OFF SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103 DURING OFF SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104 AFTER THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105 HOW TO MOVE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105 IF THE FUEL HAS BEEN COMPLETLY DEPLETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105 BATTERY IS DISCHARGED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106 OTHER TROUBLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108

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INTRODUCTION ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108 BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110

MAINTENANCE GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 MAINTENANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 NOTES REGARDING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 NOTES REGARDING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 NOTES REGARDING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 NOTES REGARDING LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 FUEL COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 SELECTION ACCORDING TO THE AMBIENT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 HEES SYNTHETIC BIODEGRADABLE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 MULTIPURPOSE BUCKET AND PALLET FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 TELESCOPIC ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 OFFSET BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 CRITICAL PARTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 FUEL SUPPLY SYSTEM - A90002 TO A90008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 FUEL SUPPLY SYSTEM - A90009 AND UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 DELIVERY RETURN HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 LOADER AND BACKHOE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 OPERATOR’S SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 STANDARD TORQUE FOR BOLTS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 SPECIFIC TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 WHEN DEMOLITION HAMMER IS USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 EVERY 10 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 FIRST 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 EVERY 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

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INTRODUCTION FIRST 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 EVERY 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 FIRST 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 EVERY 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 EVERY 1000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 EVERY 2000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 EVERY 4000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 AIR CLEANER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 CAB AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 FUEL WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 FRONT WHEEL TOE IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 BRAKING EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 BRAKE PEDAL STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 LOADER RETURN TO THE DIG POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 DEMOLITION HAMMER INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 CHANGING THE HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 CHANGING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 VARIOUS CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 HYDRAULIC SYSTEM OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 DRAINING WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 EVERY 10 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 FIRST 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 HEES OIL TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 EVERY 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 RADIATOR FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 BRAKE SYSTEM OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 DRIVE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 FRONT AND REAR AXLE JOINTS AND FRONT PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 FIRST 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 EVERY 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 A/C COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

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INTRODUCTION RADIATOR OUTSIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 CONDENSER OUTSIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 FRONT AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 REAR AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 TRANSMISSION OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 WHEEL LUG NUT TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 FIRST 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 EVERY 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 HYDRAULIC SYSTEM OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 EVERY 1000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 FRONT AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 REAR AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 TRANSMISSION OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 TRANSMISSION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 ENGINE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 EVERY 2000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 HYDRAULIC SYSTEM OIL AND SUCTION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 RADIATOR COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 BRAKE SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 ALTERNATOR AND STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 A/C SYSTEM COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 EVERY 4000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63 A/C DEHYDRATING FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63 A/C COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63 LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64 BEFORE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64 DURING STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 AFTER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

SPECIFICATIONS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 LOADER, BACKHOE - STANDARD ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 LOADER, BACKHOE - TELESCOPIC ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 WB150AWS-2N STANDARD ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

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INTRODUCTION WB150AWS-2N OFFSET STANDARD ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 WB150AWS-2N TELESCOPIC ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 WB150AWS-2N OFFSET TELESCOPIC ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

OPTIONAL ATTACHMENTS AUTHORIZED OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 BASIC PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 OPTIONAL EQUIPMENT MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 FRONT END LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 BACKHOE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 MULTI PURPOSE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 BUCKET OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 BUCKET USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 MP BUCKET USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 PALLET FORK KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 PREPARING FORKS FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ROTATING FORKS FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 FORK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 FORK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 OPTIONAL FRONT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 BACKHOE TELESCOPIC ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 SAFETY LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 GUIDE SLACK ADJuSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 DEMOLITION HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 RULES FOR HAMMER USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 FOR CORRECT USAGE, IT IS NECESSARY TO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 ALWAYS AVOID THE FOLLOWING USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 INSTALLATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 HAMMER USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 UNIDIRECTIONAL OIL FLOW EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 STANDARD BACKHOE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

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INTRODUCTION DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 INSTALLING AND CONNECTING THE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 PPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 INSTALLING AND CONNECTING THE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 OFFSET BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 STANDARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 PPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 CLAMSHELL BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 STANDARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 PPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 OPERATING THE CLAMSHELL BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 HYDRAULIC JACK HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 DESCRIPTION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 CONNECTING THE JACK HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 DISCONNECTING THE JACK HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 USING THE HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 LOAD STABILIZER SYSTEM (LSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

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INTRODUCTION

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1SAFETY WARNING! Read and follow all safety precautions. Failure to do so may result in serious injury or death.

This safety section also contains precautions for optional equipment and attachments.

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SAFETY

SAFETY AND WARNING DECALS It is important that all safety and warning decals are in place, not damaged, covered up or removed. It is also important for the operator to be aware of the decal content and location.

LOCATION OF THE SAFETY DECALS ★ Your distributor can supply you with new replacement decals if the ones on the machine are damaged or missing. When replacing damaged or missing decals, be sure they are placed in the proper location. Additional safety or warning decals may be added to your machine if desired.

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SAFETY b Warning Decal..................................................... 312614650 Before operating this machine: •

Study the operator’s manual.

•

Be aware of all the safety decals.

•

Keep the operator’s manual with the machine at all times for reference.

c Height Decal........................................................ 312614651 It is always a good idea to be aware of your clearances around, in front, behind and especially above your work area or travel route.

Because of the additional height posed by the backhoe boom 1 m is added above the canopy when the machine is in the travel posture.

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SAFETY d Warning Decal..................................................... 312614663 •

Be sure that all personnel are at least 12 m away from any point on the machine before moving the machine.

•

Never allow anyone to stand near the machine while in operation.

•

Remember, the larger the machine the more restricted your visibility will be.

e Sudden Movement.............................................. 312614666 Shut down procedures for the machine.

•

Lower the loader bucket to the ground.

•

Lock the loader controls.

•

Curl the bucket and move the arm in towards the frame until they stop.

•

Activate the boom lock and insert the travel pin.

•

Lock the backhoe controls.

•

Engage the parking brake.

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1-5

SAFETY f Do Not Operate Tag ............................................ 312614665 This warning tag must be kept with the machine at all times and used when maintenance or repairs are performed.

g Hydraulic Oil ....................................................... 312614665 Hot oil hazard.

•

Turn the engine OFF.

•

Allow the oil time to cool down.

•

Slowly loosen the cap to relieve pressure before removing.

h Proposition 65 Warning ..................................... 306421752 •

1-6

Diesel engine exhaust.

WB150AWS-2N

SAFETY i Battery Decal....................................................... 312614664 Battery safety precautions.

•

When attaching booster cables, always make the negative (-) connection last and at a remote location away from the battery.

•

Do not smoke or allow open flames or sparks near the battery.

•

Always wear a face shield when working with batteries.

•

When charging the battery always follow proper charging instructions outlined in the Service Manual for this machine.

•

Avoid contact with battery acid. Sulfuric Acid may cause burns or damage clothing or components.

•

If you should come in contact with battery acid or spill some, flush the area immediately with water.

j Window Warning................................................. 312614661 When operating the window, be sure it is in the proper locked position to avoid sudden unexpected movement.

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1-7

SAFETY 1) Accumulator........................................................ 306521685 If your machine is equipped with an accumulator: •

When releasing the pressure or charging with gas for the work equipment circuit of machines equipped with an accumulator, be careful and follow the instructions given for handling the accumulator.

•

The accumulator is charged with high pressure nitrogen gas which is extremely dangerous, read the following items and be careful to handle the accumulator properly.

•

Do not make any holes or bring any open flames or heat close to the accumulator.

•

Do not weld on the accumulator.

•

The gas must be released before disposing of the accumulator, ask your distributor to do this for you.

1! Air Filter............................................................... 312614659 Air filter replacement:

1-8

•

Keep element free of damage or oil deposits.

•

For cleaning or replacement of the element, see AIR CLEANER CARTRIDGE on page 3-23.

•

Do not use oil on this filter element.

WB150AWS-2N

SAFETY 1@ Hot Coolant Hazard ............................................ 312614649 To prevent the sudden release of hot coolant: •

Turn the engine OFF

•

Allow the system time to cool down.

•

Slowly loosen the radiator cap to relieve any pressure before removing it.

1# Fuel Tank ............................................................. 312614660 Fuel tank precautions.

•

If the fuel tank should need draining, see FUEL TANK on page 3-52.

1$ Do Not Use Ether ................................................ 312614653 Use of starting aids.

•

Use of any starting fluids including ether may cause explosion or damage the engine.

•

Never use starting aids to start the engine.

WB150AWS-2N

1-9

SAFETY 1% Running Engine Warning................................... 312614654 Rotating engine parts.

•

Keep away from rotating or moving engine parts.

•

Keep clear of the engine fan and fan belt.

1^ Pinch Point Danger ............................................ 312614658 Crush or pinch points located on the machine.

•

Operate the machine from the operator’s seat only.

•

During operations, never place any part of your body near the swing area of the machine.

1& Proposition 65 Warning ..................................... 306521691 •

1-10

Battery.

WB150AWS-2N

SAFETY 1* Seat Belt Warning ............................................... 312614657 The importance of using the sear belt equipped with your machine. •

If the machine is equipped with a seat belt and rollover protective structure, OSHA law requires that the operator remain within the confines of the rollover protective structure, with seat belt fastened snugly around their waist before operating the machine.

1( Blocking Wheels................................................. 312614656 Parking on an incline. •

Always block the wheels when parking on an incline.

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1-11

SAFETY 2) Start Bypass Danger .......................................... 312614652 Jump starting the machine from outside the operator’s cab.

•

Never bypass the starting circuit by jump starting your machine at the starter or any other point outside of the operator’s cab.

•

Always start the machine from the operating position in the operator’s cab with the seat belt fastened around your waist.

2! Loader Dangers .................................................. 312614648 Before doing any maintenance on the front part of the machine and the bucket, the loader equipment must be raised and locked: •

Empty the bucket completely.

•

Raise the loader and install the safety bar.

•

Slowly lower the loader cylinder until all movement stops.

•

Lock the loader controls.

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WB150AWS-2N

SAFETY 2@ ROPS Structure .................................................. 312614647 Role Over Protective Structure cautions. •

Never weld, drill or cut on the ROPS

•

If it becomes damaged, contact your distributor.

2# Brake Fluid .......................................................... 312614655 Use the correct fluid in the hydraulic braking system. Using the wrong brake fluid may cause damage to the brake system which could lead to brake failure.

2$ Backhoe Levers Operation

WB150AWS-2N

1-13

SAFETY 2% Machine Damage •

Do not swing boom into stabilizers.

2^ Plate Control Scheme ........................................ 312614612

1-14

WB150AWS-2N

SAFETY 2& Loader Lever Control This decal is for the safety lock levers and switches on your loader work equipment. It shows: •

Loader lever lock.

•

Bucket positions.

•

Switch functions.

2* Lubrication .......................................................... 312614602 This decal is the lubrication chart for your machine it contains information on: •

Lubricating time intervals.

•

Lubrication points.

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1-15

SAFETY 2( Equipment Fuse Decal ....................................... 312614668

2^ Engine Fuse Decal.............................................. 312614669

1-16

WB150AWS-2N

SAFETY LOCATION OF THE PICTOGRAM DECALS •

Your distributor can supply you with new replacement pictogram decals if the ones on the machine are damaged or missing.

•

When replacing damaged or missing pictogram decals, be sure they are placed in the proper location.

•

Additional safety or warning decals may be added to your machine if desired.

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SAFETY

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WB150AWS-2N

SAFETY DECALS DEFINED DANGER IN THE WORK AREA ................................ 306421689 Do not approach or stand near the work equipment operating radius when the loader is raised.

ENGINE COMPARTMENT MOVING PARTS............. 312614646 Keep clear of moving parts inside engine compartment.

FILL THE SYSTEM WITH HEES TYPE OIL HEES is a synthetic, biodegradeable type oil that is used only in the hydraulic oil tank.

ENGINE OIL FILTER ..................................................3F05B2626 FUEL FILTER .............................................................3F05B2627

ENGINE AIR FILTER..................................................3F05B2628 ENGINE COOLANT ................................................... 355614626

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1-19

SAFETY ENGINE COOLANT PRESSURE...............................3F05B2633 HYDRAULIC OIL LEVEL ...........................................3F10B2604

HYDRAULIC OIL FILTER...........................................3F19B2605 TRANSMISSION OIL LEVEL

TRANSMISSION OIL FILTER ANCHOR POINT ........................................................3F10B2608

EMERGENCY EXIT ....................................................3F10B2610 BOOM LOCK.............................................................. 360714706

SWING LOCK............................................................. 360714705 BRAKE FLUID

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SAFETY

SAFETY RULES AND PRECAUTIONS GENERAL SAFETY RULES Only trained and authorized personnel shall be allowed to operate and service this machine. Before operating this machine it is important to study the operator’s manual thoroughly and become familiar with all controls and safety decals. Keep this manual with your machine at all times for easy reference.

Safety must always be the operator’s most important concern.

Never operate a machine that is unsafe or in poor operating condition. Always perform a preoperational check on your machine before operating it. If the machine is equipped with a seat belt and rollover protective structure, OSHA law requires the operator remain within the confines of the rollover protective structure, with the seat belt fastened snugly around their waist before operating the machine.

OSHA law states if your equipment is designed for operation by one person, it is for one person only, never allow other personnel to ride on your machine. Never leave your machine running and unattended. Always park the machine in a level area, lower any work equipment to the ground, set the parking brake, lock the controls and turn the engine off before exiting the operator’s compartment.

Be sure that all personnel are at least 12 m away from any point on the machine before moving or operating the machine. Never allow anyone to stand near the machine while in operation. Remember, the larger the machine the more restricted your visibility will be.

If pedestrians are in the area proceed slowly and sound your horn. Keep in mind, pedestrians have the right away, and a loaded or smaller machine has the right away over an unloaded machine. Never use your machine for tasks it was not designed for, damage to the machine or injury to the operator may result. Follow all safety rules, precautions, and instructions when operating or performing maintenance on the machine.

It is the owner and /or operator’s responsibility to replace any safety or warning decals if they are defaced or removed from the machine. Think before you act, study the job carefully. Careful operator’s and service personnel are the best insurance against accidents.

The operator of this machine must be alert, physically fit, and free from the influences of alcohol, drugs or medications that might affect there eyesight, hearing, or reactions.

When working with another person on a work site, or during traffic control, be sure all personnel involved understand all hand signals that are to be used.When leaving a job site for long periods of time always lower all work equipment to the ground, neutralize work equipment controls and lock and secure your machine properly to avoid tampering by other personnel.

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SAFETY Never drive up to anyone standing in your path of travel. Always be sure all personnel are standing to the side when you approach them and acknowledge your approach. Follow all rules relating to safety as outlined in this manual and by your company, never get involved in horseplay.

SAFETY FEATURES Be sure all guards and covers are in place especially after servicing the machine. Have guards or covers repaired immediately if they are damaged, see PRECAUTIONS BEFORE STARTING WORK on page 1-27.

Use safety equipment such as safety locks and seat belt properly.

Never remove any safety features. Always keep them in good operating condition. Always secure the machine in a safe position, see PARKING THE MACHINE on page 2-87.

Seat belt: see SAFETY SEAT BELT on page 2-77. Improper use of safety features could result in serious bodily injury or death. Be sure the machine has the correct equipment required by local rules and regulations.

PERSONAL PROTECTIVE EQUIPMENT If your machine is equipped with safety equipment OSHA law requires this equipment to be used when operating your machine.

Avoid loose fitting clothing, jewelry and loose long hair. These can catch on controls or in moving parts and cause serious injury.

Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine.

Always wear safety goggles, hard hat and heavy gloves, if your job involves driving pins with a hammer or cleaning the air cleaner element with compressed air.

Check to be sure no one is near your work area. Check to be sure all personal protective equipment are in good condition before using.

UNAUTHORIZED MODIFICATIONS Any modification made without authorization can create a hazards. Before making any modifications, consult your local distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modifications.

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SAFETY LEAVING OPERATOR’S COMPARTMENT Below are listed procedures that must be followed when exiting the operator’s cab.

1. Park the machine in a level area, lower all work equipment to the ground.

2. Engage the parking brake.

3. Place the safety lock lever for the loader control in the (LOCKED) position.

4a. Place safety lock lever for backhoe controls in the (LOCKED) position.

5. Remove the ignition key and keep the key with you.

6. Use the key to lock and secure all the equipment locks. This will prevent other unauthorized personnel from tampering with your machine. Keep in mind you are responsible for securing your machine.

Remark Never leave the machine running and unattended, even for a moment.

Work equipment; see PARKING THE MACHINE on page 2-87.

Lock, see SAFETY LOCK USAGE on page 1-38.

4b. Engage the switch to lock out the joystick levers.

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1-23

SAFETY MOUNTING AND DISMOUNTING Use all the hand holds and step plates on your machine. Never jump off or on to the machine.

Before getting on the machine, if there is any oil, grease, or mud on your shoes, rails, steps or platforms, wipe it off immediately, always keep these areas clean, and in good condition.

Never get on or off a moving machine. These actions may lead to serious injury. Always bring the machine to a full stop. Be sure the machine is at a full stop, the equipment lowered and the parking brake set before entering or exiting the machine.

Never hold any control levers or the steering wheel when getting on or off the machine.

When getting on or off the machine, always face the machine and maintain a Three Point Contact (both feet and one hand or one foot and both hands) with the handrails, steps and platforms to ensure that you support yourself properly.

CHECKING THE REAR VIEW MIRRORS Make sure that the rear view mirror is clean and correctly positioned. The operator should be able to see the rear of the machine, without moving the upper body while driving the machine.

If the mirror moves during operation, stop the machine and readjust the mirror before resuming work. If the mirror falls off the machine, stop the machine and make the needed repairs before continuing with work. Check the rear view frequently while working, especially before backing up, to ensure that no person, fixed obstacles, or other machines are in the work area.

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SAFETY FIRE PREVENTION FOR FUEL AND OIL Fuel and oil are flammable. Fuel is particularly flammable and can be hazardous. Always observe the following: •

Keep any open flames away from flammable fluids.

•

Stop the engine and do not smoke when refueling.

•

Tighten all fuel and oil caps securely.

•

Refueling or adding oil should be made in well ventilated areas.

•

Keep oil and fuel in its proper place.

•

When refuelling, hold the fuel gun firmly and keep it constantly in contact with the filler until you have finished, in order to avoid sparks due to static electricity.

•

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

•

Do not fill the tank completely, in order to leave room for the fuel to expand.

•

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

PREVENTING BURNS Wear gloves and safety goggles when checking any fluid levels: engine oil, hydraulic oil, engine coolant, transmission fluid.

Before checking the engine coolant, engine oil, or hydraulic oil, stop the engine and let the fluids cool down before attempting to check the level. If you don’t, the hot fluids may spurt out and cause burns. Slowly loosen the radiator cap to release the internal pressure or the hot coolant may spurt out and cause burns.

DUST HAZARD PRECAUTIONS Dust can be hazardous to your health if it is inhaled. Komatsu does not use asbestos in its products, but if you handle materials containing asbestos fibers or other dust materials during demolition operations, always do as follows.

•

Never use compressed air for cleaning.

•

Use water to keep down the dust when cleaning.

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1-25

SAFETY •

If there is a danger there may be asbestos dust in the air, operate the machine with the wind to your back whenever possible. Use an approved respirator. Do not allow any other person into the area during operation.

•

There may be a danger that non genuine parts may contain asbestos, use only genuine Komatsu parts.

•

Always observe rules and regulations related to the job site and working environment.

CRUSH OR PINCH POINT DANGERS Never stand under or place any part of your body between the movable components such as the work equipment and cylinders or between the machine and work equipment. Keep in mind, when the work equipment is operated, the clearance will change, this may lead to serious personal injury or death. Never drive up to any one standing in front of a solid object or your path of travel.

The brakes could fail or the machine could slide on a slippery surface causing injury or even death.

FIRE EXTINGUISHER AND FIRST AID KIT As a precaution if a fire or an injury should occur, always keep a fire extinguisher and first aid kit in the machine and do as follows: •

Be sure that fire extinguisher is in good condition and read the label on it to ensure you know how to use it. Keep a first aid kit in the storage area. Check the kit periodically and make any additions if necessary. Keep a list of emergency phone numbers in case of an accident.

INSIDE OPERATOR’S COMPARTMENT When entering the operator’s compartment, always remove mud and oil from the soles of your shoes. If you operate the brake pedal with mud or oil on your shoes, your foot may slip and may cause an accident.

After using the ashtray, make sure matches or cigarettes are properly extinguished and be sure to close the lid. If the ashtray is left open, there is danger of fire. Do not leave lighters or aerosol cans lying around the operator’s compartment. If the temperature inside the operator’s compartment get’s too high, there is danger that the lighter may explode. Do not stick suction pads to the window glass. Suction pads may act as a lens and could cause fire.

Do not use cellular telephones inside the operator’s compartment when driving or operating the machine. Never bring any dangerous objects such as flammable or explosive items into the operator’s cab. To ensure safety, do not use the radio or music headphones when operating the machine. Keep the operator’s compartment clean, never allow trash or tools to accumulate, these may hinder the operation of the controls or pedals.

When operating the machine, do not put your hands or head out of the window or beyond the protection of the ROPS. Always use the seat belt equipped with your machine. Even when using the loader or backhoe unit. Be sure the seat belt is fastened snugly around your waist before operating the machine.

1-26

WB150AWS-2N

SAFETY PRECAUTIONS WHEN USING ROPS The ROPS (Roll Over Protective Structure) must never be removed from the machine. The ROPS is installed to protect the operator if the machine should roll over. It is designed not only to support the load if the machine should roll over, but also to absorb the impact of the energy.

The ROPS fulfills all the regulations and standards for all countries, but if it is modified without authorization or is damaged, the strength may be reduced and it may not able to fulfill its function properly.

PRECAUTIONS FOR ATTACHMENTS When installing and using an optional attachment, read the instruction manual for the attachment and information related to the attachments.

Do not use attachments that are not authorized by your distributor. Use of unauthorized attachments could create a safety problem and adversely affect proper operation and useful life of the machine.

Any injuries, accidents, product failures resulting from use of unauthorized attachments will not be the responsibility of Komatsu.

PRECAUTIONS BEFORE STARTING WORK Before starting your work operations it is important to perform several procedures to be sure your equipment is in a safe operating condition. It is also important to be aware of the hazards involved when operating your machine.

PRE OPERATIONAL CHECKS Before starting your machine and preceding with any work operations it is important to be sure your machine is safe to operate.

Below is a list of some basic items to check before any work is to begin. If any problems are found during your pre operational check, have them repaired immediately. Never operate a machine that is unsafe, damaged or in need of repair.

PERFORM A WALK AROUND CHECK OF YOUR MACHINE 1. Look for any obvious missing or damaged items. Check the condition of the loading and backhoe buckets, look for loose or missing attachment pins, damaged surfaces or missing parts.

2. Check the condition of all visible hydraulic hoses, look for worn or leaking fittings, cut, scuffed or cracked hose surfaces. If any hose is found to be worn, cracked or leaking have it repaired or replaced immediately.

3. Check for leaking or damaged hydraulic cylinders. If any cylinder is damaged or leaking have it repaired immediately.

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1-27

SAFETY 4. Inspect the mechanical lift, dump and backhoe arms and pivot points. Look for any loose or missing parts, cracked, bent or damaged areas.

5. Be sure all safety decals are in place and are not damaged.

Be sure they are clean and visible for all personnel to see.

6. Check the condition of the front and rear tires. Look for excess wear or cut surfaces, objects imbedded in the tire or under inflation.

7. Check under the machine for any build up of debris, trash or leaks. Remove any debris that is found and have the leak checked by authorized personnel.

8. Inspect the fuel and hydraulic tanks for damage or leaks. Be sure the fill caps are installed and locked in place.

9. Be sure the steps are not damaged or covered with mud.

10. Check the condition of the cab. inspect the windows, mirrors, hand holds, work lights, directional and canopy for any damage or missing parts. Be sure all locks are functional.

11. Check the exhaust stack, be sure it is not damaged, kinked or restricted in any way. Be sure the exhaust outlet is facing away from the cab and is not restricted.

UNDER THE HOOD 1. Open the hood and check all fluid levels. be sure they are at the specified level outlined in the maintenance section.

2. Check the engine and radiator for any build up of trash, wood chips, rubbish, leaves or other flammable materials. If flammable materials are found as well as excess build up of oil or dust, remove the flammable material or have the engine cleaned.

3. Be sure the hood closes properly and will lock securely to prevent tampering by others.

IN THE OPERATOR’S CAB 1. Check the condition of the cab floor. Be sure it is clean and free from tools, objects, excess dirt, trash or grease.

2. Check to be sure both doors open and close properly. Be sure the right door is unlocked for safety purpose.

3. Check the windows for cleanliness, remove any stickers or objects pasted to the windows.

4. Make sure the fire extinguisher is in place and in operating condition.

5. Be sure the operator’s manual, safety manual and all cab safety decals are in place and in good condition.

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WB150AWS-2N

SAFETY 6. Check to be sure the seat belt and seat works properly.

START UP CHECKS

When performing start up checks, be sure your machine is in a well ventilated area.

Start the engine and allow it to idle at a low RPM. 1. Check the operation of all gauges and warning systems. Be sure they all work and come up to normal operation.

2. Check the operation of all switches. Be sure the lights, wipers, directional, horn and warning flashers and alarms work properly.

3. Check the brakes, throttle operation and steering wheel. Be sure they are clean and free from dirt or grease.

4. Check the operation of all work controls.

Remark It is important that a pre operational check be performed at the beginning of your work shift, even if you are taking the machine operations over from another operator, always perform a pre operational check before you start work.

ROOM VENTILATION Exhaust gases are deadly. If starting the machine inside a building, connect a suction duct to the exhaust pipe.

STARTING YOUR WORK OPERATIONS •

Before operating the machine, walk around it and check for people or objects that might be in the way. Do not start the engine if warning tags have been attached to the steering wheel or control levers. Sound your horn to warn others in the area before starting the engine or moving the machine.

•

Operate the machine in a seated position only, with the seat belt fastened snugly around your waist. Do not allow anyone in the cab or on the machine during operations.

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1-29

SAFETY WORK SITE HAZARDS Before proceeding with any excavating operations it is important to be aware of the hazards involved with this operation. Below is a list outlining what to do to avoid some of these hazards.

•

Before starting any excavating operations, contact all utility departments in your area and have them identify and mark any underground system locations, gas lines, water lines, electrical lines, sewer lines, etc. Check your work area for any unusual ground conditions. Make sure your work area is as level as possible and you will be able to maneuver your work equipment or machine easily.

•

If you will be working near a high traffic area, pedestrians or cars, have a dedicated worker available to direct traffic or install safety fencing around your work site. Always be aware of all your work site dangers or distractions.

FIRE PREVENTION •

Completely remove all wood chips, rubbish, paper and other flammable materials that may have accumulated inside the engine compartment, since they can cause fires.

•

Check the fuel and hydraulic system pipes for leaks and if necessary repair them. Wipe up any excess oil, fuel or other flammable fluids.

•

Make sure that fire extinguishers are available in the working area.

WORKING CLEARANCES It is always a good idea to be aware of your clearances around, in front, behind and especially above your work area or travel rout.

Because of the additional height posed by the backhoe boom 1 m is added above the canopy that cannot be seen by the operator when the machine is in the travel posture. Some basic safety precautions to prevent risk are: •

When working or traveling in an area where clearances are a problem, travel at a slow cautious speed. If you are not sure of your clearances, request the aid of another person who can guide or warn you if you get too close to objects.

•

Be aware of the dangers when working around overhead power lines, high humidity may pose an electrical hazard even if your machine clears the overhead power lines.

•

1-30

If your machine should come in contact with overhead electrical lines, stop the machine and remain on the machine until the power company clears the lines and it is safe to get off or move the machine. If low power lines pose a greater hazard, ask the power company to remove the lines until your work is finished.

Voltage

Min. Safe Distance

6.6kV

3m

66.0kV

5m

275kV

10 m

WB150AWS-2N

SAFETY RULES FOR ROAD TRAVEL The machine is equipped with multifunction safety locks that must be used both for maintenance operations and road travel.

When necessary to travel on roads, proceed as follows: 1. Raise the backhoe boom and engage the safety coupling for the arm, boom and bucket.

2. Center the boom and install the lock pin.

3. Connect the safety cables to prevent accidental lowering of the outriggers.

4a. Lock the backhoe control levers using the safety lock equipped with the machine.

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1-31

SAFETY 4b. Engage the switch to lock out the joystick levers.

5. Raise the loader bucket to a safe travel height of 30 to 40 cm from the ground.

6. Lock the loader control levers using the safety lock equipped with the machine.

7. Be sure the brake pedals are locked together and the 4 wheel drive feature is disengaged.

8. Obey all traffic rules when traveling on local and state roads.

Always travel at a safe controllable speed.

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SAFETY RULES FOR TRAVELING IN REVERSE Traveling in reverse may pose several hazards. Below is a list if some basic rules to follow when traveling in reverse.

•

Be sure the area behind you is clear of people or objects that might be in the way.

•

Before moving your machine, sound the horn to warn others in your area you are moving.

•

When operating in areas that may pose a hazard or has poor visibility, designate a person to direct your movements.

•

Do not rely totally on the machines mirrors, keep in mind there are blind spot when using the mirrors.

•

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.

•

It is necessary to make sure that there is no one behind the machine before travelling in reverse.

•

The machine is equipped with a back up alarm b. Before any reversal make sure that the alarm functions correctly.

TRAVELING ON ICY/SNOW COVERED SURFACES If the ground is icy or covered with snow, the response of the machine to the movements of the steering wheel may not be as precise as expected. To limit the risk from reduced maneuverability, proceed as follows: •

Engage the four wheel drive system. Remember, the four wheel drive system will not effect your braking.

•

Travel at a slow safe speed. Avoid rapid accelerations or breaking.

•

Remember your stopping distances are reduced during slippery conditions.

WORKING ON LOOSE OR UNSTABLE GROUND To limit the risk when working in these areas: •

Avoid operating the machine too close too the edge of a cliff, open trenches or ditch lines. These areas may collapse under the weight of your machine causing serious damage to the machine or injury to the operator.

•

Keep in mind after a heavy rain or thaw, the surface conditions become worse and less stable.

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1-33

SAFETY VISIBILITY •

When visibility decreases due to darkness, turn on the road lights, working lights, or both. If reduced visibility is a result of fog, smoke, white out conditions (blizzard), or heavy rain, stop the machine in a safe place as soon as possible. Wait for the conditions to improve before resuming work.

PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT Working in tunnels, beneath bridges or under cables, telephone or power lines, and any other situation where the height is limited, ensure that working with the backhoe or loader will not cause any damage.

TRAVEL POSITIONS The operator must be seated with the seat belt fastened snugly around the waist. Position the seat so you are comfortable and able to see all areas around you and have easy access to all controls. The backhoe must be fully retracted and locked in place as well as both outriggers, see BACKHOE LOCKS on page 1-40.

Always keep the bucket at least 50 cm above the ground.

A section of the backhoe boom is 1 m above the canopy. The section of backhoe above the canopy cannot be seen by the operator when the machine is in the travel posture.

Never shift the transmission into neutral when on a slope or hill. If the machine should lose control or slide on the slope or hill, lower the loader bucket to the ground to help stabilize the machine.

TRAVELING ON SLOPES Before traveling up a slope, check the fuel supply so the machine does not run out of fuel while on the slope. And check the brakes to be sure they are locked and in good working condition. On hills or slopes, lower the bucket to a traveling height from 20 to 30 cm above the ground.

When traveling up a slope with an empty bucket, travel with the bucket directed in an upward position. When traveling up a slope with a loaded bucket, always keep the bucket at least 50 cm above the ground. Never raise the bucket when traveling on a slope.

Remark If the machine should start to tip with the bucket loaded, immediately lower the bucket to the ground to help stabilize the machine and lower the center of gravity.

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WB150AWS-2N

SAFETY When traveling down a slope or hill with an empty bucket, travel with the bucket facing downward. When traveling down a slope with the bucket loaded, back the machine down the slope with the bucket facing the top of the incline. Always keep the bucket at least 50 cm above the ground. Never raise the bucket when traveling on a slope.

Remark If the machine should start to tip with the bucket loaded, immediately lower the bucket to the ground to help stabilize the machine and lower the center of gravity.

Always travel straight up or straight down the slope. Never turn or travel sideways on the slope or incline. Doing so may cause the machine to rollover.

Never turn on a slope or travel across a slope. Never change speed ranges when on a slope or hill. Always set the machine in a low speed range for travel on a hill or slope. Never use the feature buttons when the machine is on a slope or loss of control may result.

Always be aware of your travel surfaces. Wet leaves, wet grass, or mud may hinder control of the machine.

BUCKET PRECAUTIONS When hauling with a loaded bucket, keep the bucket at least 50 cm above the ground.

To reduce the risk when soil must be dropped over an edge or a cliff, dump one pile a safe distance from the edge. Dump a second pile between the backhoe and the first pile. Use the second pile to push the first pile over the edge. Repeat this procedure as many times as needed until only one pile remains. With the last pile, use extreme caution to push it over the edge.

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SAFETY While pushing a pile of soil over the edge, the load becomes lighter. Thus, the speed of the machine automatically increases.

Be alert and ready to adjust the speed of the machine, including using the service brakes.

To prevent the machine from tipping when it has a fully loaded bucket, avoid fast starts, sudden stops, and sharp turns.

Never raise the bucket too high or tip the bucket back too far when handling awkward loads, round or cylindrical objects, scrap or timber or the load can fall onto the cab and cause death or serious injury to the operator and damage the cab.

Never use the bucket or boom arm as a crane, drag line, or hoist.

Use the backhoe for its intended use only. Performing non-approved operations can cause serious injury, and breakdowns that void the warranty.

PARKING THE MACHINE The loader backhoe is set up to be parked in a secure manor. If you will be leaving the machine for a short or long period of time, use all the security features equipped with the machine.

PARKING ON LEVEL GROUND 1. Find a flat level surface to park on.

2. Place the directional control in the neutral (N) position.

3. Lower the work equipment to the ground 4. Lower the outriggers to the ground.

5. Turn the engine off and remove the ignition key.

6. Set the parking brake.

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SAFETY PARKING FOR LONG PERIODS OF TIME The possibility of having an unauthorized person tampering with the machine when it is unattended is significant. Besides performing the same procedures listed above, use the locks when the machine is unattended.

Keep in mind you are responsible for the security of your equipment when it is unattended. Properly locking and securing the equipment will help in protecting it from unauthorized access.

PARKING ON AN INCLINE Although parking on a slope is not recommended, certain situations dictate that you do. Lower the front end loader and dig the leading edge into the ground several inches. Be sure the bucket is tipped forward to help keep the digging force in a downward position. Move the control lever into the float position. Place blocks under both front and rear wheels to help secure the machine in place.

When setting the backhoe on the ground, dig the bucket teeth into the ground to help hold the machine in place. Do not raise the back end of the machine up when doing this procedure.

Never park the machine with the wheels off the ground. Always fully lower the work equipment and machine to the ground when parking the machine.

After performing the above, do the following: 1. Place the directional control in the neutral (N) position.

2. Lower the work equipment to the ground.

3. Turn the engine off and remove the ignition key.

4. Apply the parking brake.

5. Apply all locks.

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SAFETY

SAFETY LOCK USAGE When it is necessary to perform maintenance, repairs or travel on roads, it is important to be aware of the safety locks equipped with the machine. It is also important to know how to use these locks and when to use them. Failure to observe these precautions and use the safety equipment may result in a serious accident or injury.

Use safety locks when: Performing any maintenance on the machine.

When traveling on roads.

When the machine will be unattended.

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SAFETY LOADER CYLINDER LOCK The front end loader cylinder lock b must be used any time you will be performing maintenance on the machine with the front end loader raised. To use the cylinder lock: 1. Remove the cylinder lock assembly pin c that holds onto the lock unit b.

2. Using both hands lower the lock unit b down from it’s storage position and remove it from the boom arm.

3. Raise the front end loader unit completely in the air extending the lifting cylinders.

4. Install the cylinder lock b in the position shown. Keep the safety pin boss against the boom cylinder gland nut.

5. Insert the safety pin c completely into the predrilled holes. Lock the safety pin in place with the smaller pin provided.

6. Slowly lower the front end loader unit it makes contact with the cylinder lock.

7. Check to be sure the cylinder lock is securely in place before proceeding with any procedures under the front end loader.

8. Using the safety lock d in the operator’s cab, lock the loader control before proceeding with any repair or service operations.

9. After completing the work, unlock the safety lock d.

Raise the front end loader up slightly to relive tension on the cylinder lock.

10. Carefully remove the small pin and the safety pin c. With both hands, remove the cylinder lock b completely.

11. Lower the front end loader to the ground.

12. Reinstall the cylinder safety lock b to the storage location on the left boom arm.

Always keep the cylinder safety lock with the machine. Never use a substitute or damaged cylinder lock. If it is missing or damaged, replace it immediately.

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SAFETY BACKHOE LOCKS The backhoe locks secure the backhoe in a travel position. Use these locks when traveling with the machine or using the front end loader. To use the backhoe lock: 1. When the machine is in operation and the backhoe is being operated, disengage the backhoe boom lock.

2a. To use the backhoe boom lock, press the switch b.

2b. To use the backhoe boom lock, press the switch b.

3. Retract the arm, and telescoping arm if so equipped, and curl the bucket.

4. Press the boom lock switch b to engage the boom locking device c.

5. Center the backhoe unit to align the lock pin holes in the backhoe mounting boss.

6. Remove the centering pin d from it’s holding location and insert it in locking holes in the backhoe mounting boss.

7. Be sure the pin d drops down completely and is flush with the top of the backhoe boss. After installing the lock pin d, the backhoe assembly will not swing.

8a. Lock the backhoe levers e using the locking lever f. Move the levers to be sure they are locked.

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SAFETY 8b. Engage the switch f to lock the joysticks. Move the joy sticks e to be sure they are locked.

9. If traveling or using the front end loader for a long period of time, lock the outriggers in place to avoid possible hydraulic drift.

A. Unlock the lever f to raise the outriggers.Retract both outriggers completely.

B. Install the locking safety cables g on both outriggers and be sure to lock the wobble stick lock f.

Remark The lock pin and the safety cables must remain with the machine. If they are lost or damaged, replace them.

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SAFETY

TRANSPORTING THE MACHINE

Before transporting the machine, ensure that the transport truck is capable of supporting the machine’s weight. Perform the loading and unloading of the machine on flat, dry ground and at a safe distance from the edge of the road or ditches.

Position chocks behind and in front of each tire of the transport vehicle before loading or unloading the machine. Ensure that the ramps are of the same length and parallel to each other, and firmly anchored to the transport truck. Check that the ramps can safely support the machine; if not, purchase new ramps. Remove any grease, oil, or ice from the ramps before unloading or loading the machine. Maximum ramp inclination is 15°.

LOADING AND SECURING THE MACHINE Locate the tie down and transportation brackets on the machine.

Be sure they are in good condition.

Angle the loading ramps not greater than 15°. Position the machine squarely with the ramps. Raise the loader bucket high enough to clear all surfaces. Travel straight up the ramp at a slow speed in low range with the bucket facing forward. Do not change direction when on the ramp; if repositioning is needed, back down the ramp and realign the machine to the ramps. After loading the machine, rest the front bucket on the floor, set the machine in neutral and apply the parking brake. Lower the backhoe onto the floor. Set all control locks, including the backhoe lock pin. Turn the ignition off and remove the key. Secure the machine with chains at the anchor points. Place tire chocks behind and in front of each wheel.

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SAFETY

EMERGENCY RECOVERY The machine is equipped with emergency recovery hooks for emergency recovery only. The machine is not designed to be towed, especially by the front loader or backhoe. These hooks are only for temporary use to get the machine into a secure area so the proper repairs can be made.

MOVING THE MACHINE If the machine cannot move under its own power, it is important to follow some simple procedures. Place all the controls in neutral and disengage the four wheel drive system before moving the machine.

Use recovery hooks and towing cable rated at 6200 kg. Tow the machine just far enough to perform the essential repairs. Never tow the machine at an angle. Always tow the machine in a straight line. Ensure the tow cables are the same length before towing.

Never stand next to the tow lines when towing the machine.

The cable or chain could break causing injury. Always stay clear of the towing equipment.

NEVER use a cable that has cut strands (A), has kinks (B), or has a stretched section (reduced diameter) (C).

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SAFETY

PRECAUTIONS DURING MAINTENANCE All maintenance performed on this machine must only be performed by trained and authorized personnel. When performing maintenance it is important to follow the outlined maintenance procedures and safety information outlined in this manual and in the Shop Manual for this machine.

WARNING TAGS Before performing any maintenance operations on this machine, position the machine on level and firm surface.

Lock the equipment controls, remove the ignition key and tag the steering wheel.

Alert all personnel in your area that the machine is down for maintenance. If necessary, tag the machine around specific points to warn others that this machine is down for maintenance.

If the machine will be down for maintenance for a long period of time, be sure to check and see if the warning tags are still in place before you start your repair procedures the next day.

EQUIPMENT STORAGE 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 someone, they can cause serious bodily harm.

When assembling or removing any equipment, make sure that the ropes and the lifting hook are in good conditions and properly dimensioned for the load to be lifted.

WORKING UNDER THE MACHINE Always use approved jack stands to support the machine when performing maintenance under the chassis. Never rely on hydraulic jacks or the machines work equipment to support the machine when working under or on the machine.

Always lower the work equipment to the ground or in any case to their lowest position before performing service or repairs under the machine. Always lock the machine tires securely. Do not work under the machine, if this is not sufficiently supported.

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SAFETY USING DROP LAMPS Use only approved anti explosion proof lamps when checking fuel, oil, or the batteries. Non approved lamps can cause an explosion or fire.

KEEPING THE MACHINE CLEAN Never use flammable liquids to clean your machine. Use only approved non flammable cleaning solvents to clean parts or the machine itself.

Avoid using high pressure steam cleaners or caustic soaps to wash the machine if possible. Steam cleaning or using caustic soaps may damage paint, wiring or sensitive electrical components.

Never use high pressure water or flood the inside of the operator’s cab. Doing so may damage sensitive electrical components.

When pressure washing, use high pressure hot water and mild grease cutting soaps.

Always grease the machine after cleaning to push any water out of the pivot point connections.

ENGINE OPERATING DURING MAINTENANCE If during maintenance the engine must be run, be sure all work equipment is locked. Have someone remain in the operator’s seat while the engine is running. This is if the engine must be shut down quickly.

RULES FOR REFUELING THE MACHINE Always clean up any spills. Grease, fuel, oil or coolant spills can pose a trip hazard if not moped up immediately. Be sure you are adding the correct fluids to the proper location. Mixing fluids can cause damage to internal components.

When refueling or adding any fluids, be sure you are in a well ventilated area. Never smoke or allow open flames near you while you are refueling the machine.

Never mix gasoline with diesel fuel. Gasoline is extremely flammable and could cause an explosion. Do not fill the fuel tank completely, leave room for the fuel to expand.

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SAFETY COOLING SYSTEM PRECAUTIONS Never add coolant to a hot or warm engine. Always allow the engine time to cool down completely before opening the radiator cap.

Never dump used coolant on the ground, in a lake, stream or in a sewer system. EPA law requires these fluids to be captured and recycled properly. Failure to do so is in violation of the law.

USING LAMPS When checking the fuel, oil, coolant or battery electrolyte levels, always use an explosion proof lamps. If such lighting equipment is not used, there is danger of fire or explosion.

ELECTRICAL PRECAUTIONS Before servicing the battery, the electrical system, or arc welding, turn the battery disconnect switch b counterclockwise and remove it. The switch is located inside the engine compartment on the left side.

BATTERY When working on the electrical system, disconnect the negative (-) battery cable b first then the positive (+) battery cable c last.

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SAFETY On completion of work, reconnect the positive (+) cable b first, then the negative (-) cable c last.

CONNECTING CABLES 1. Make sure that the ignition key is in the OFF position.

2. Connect the positive poles (+) b of the two batteries with each other A. Connect the cable of the negative terminal (-) c of the charged battery to the ground of the machine to be started B. 3. Start the engine of the machine that supplies current and increase its speed. Start the engine of the machine that does not work, see STARTING THE ENGINE on page 2-81.

DISCONNECTING CABLES 1. When the engine has started, remove the cables in the reverse order with respect to their connection.

2. Disconnect the negative cable (-) b from the earth block of the engine that has been started and then from the battery A. 3. Disconnect the positive cable (+) c first from the battery used for the starting and then from the exhausted battery B.

ALTERNATOR If electrical welding operations are to be carried out on the machine, it is necessary to disconnect the battery and the alternator.

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SAFETY STARTER Start the engine only when correctly seated in the driving position.

Do not attempt to start the engine by causing a short circuit with the terminals of the starter. This may cause fires, serious injuries and even death in case of sudden or accidental movements of the machine.

PRECAUTIONS CONCERNING THE GEARSHIFT If electrical welding operations are to be carried out on the machine, it is necessary to disconnect the connector b of the gearshift unit positioned under the steering wheel.

To reach the connector b, first remove the protection casing c.

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SAFETY HIGH PRESSURE HOSES Do not use bent, cut or cracked tubing or hoses which have been previously rejected because of leaks or other defects. Faulty hoses can burst during operation causing injury or fire.

Repair or replace any loose or faulty fuel or hydraulic lines immediately. Do not operate the machine with damaged or leaking hoses or lines.

Remember that working hydraulic systems are always under pressure. If you have to add or drain hydraulic fluid, service or inspect the hydraulic system, lower the equipment to the ground and release system pressure and residual tank pressure before starting any work.

Leaks from pressurized hydraulic lines are extremely dangerous since the spray from them can penetrate your skin and enter the bloodstream, or the eyes.

Always wear thick gloves and protective goggles when working on the hydraulic systems. Use a sheet of cardboard or plywood to search for leaks.

If you are struck by a jet of hydraulic fluid under pressure, or if you are injured even slightly, consult a doctor immediately for appropriate treatment.

HIGH TEMPERATURES AREAS When you stop the machine at the end of a job, remember the engine coolant, oil, all engine parts, exhaust stack and the hydraulic system is still hot and under pressure. If you attempt to drain engine coolant, hydraulic fluid, or engine oil under these conditions, you expose yourself to various dangers, including the risk of serious burns.

Carry out maintenance procedures described in this manual only when the machine has had time to cool down.

ROTATING PARTS Take particular care near rotating parts. Keep your body at a safe distance.

If hands, clothing, or tools become entangled in the fan blades or fan belt, severe injury may result. Keep well away from all rotating parts.

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SAFETY DISPOSAL OF WASTE MATERIALS Never dump waste fluids in a sewer system, on the ground in rivers, etc. Always drain fluids from your machine into the appropriate containers. Never drain fluids directly onto the ground. Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, filters, batteries, coolant, brake fluid and hydraulic oil.

INFLATING TIRES Always bear in mind that tires can burst while being inflated, causing serious accidents. Before servicing the tires, observe the following precautions: •

Before inflating tires, always check the wheel rims, tire walls and tread for cuts, broken cords, or other damage.

Have a tire expert perform checks and tire maintenance.

•

When inflating tires, use a protective cage, and a compressed air gun with an extension hose and pressure gauge. Make sure there is nobody in the vicinity before starting to inflate a tire. Stand at the tread end of the tire to inflate it.

•

Never exceed the inflation pressures specified for each type of tire. Always check the tire pressures on both sides of the machine.

TOOLS Only use the tools provided in the tool kit and other high quality tools. Throw away any worn, damaged, poor quality, or improvised tools.

After use, always clean the tools carefully and put them in the appropriate compartment positioned inside the seat support. If the operator wants to keep on the machine some working tools whose dimensions exceed those of the compartment positioned under the seat, he can put them in an appropriate tool case positioned on the outside of the rear part of the cab. See see TOOL CASE on page 2-78.

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SAFETY EXHAUST SYSTEM PRECAUTION The exhaust pipe b and trail pipe c remain very hot immediately after turning the engine off. If the exhaust pipe or trail pipe need servicing, wait until they cool off before attempting repairs, or you will become burned.

When reassembling the trail pipe c to the exhaust pipe b, position the trail pipe as shown. This step prevents exhaust gases from entering the cab.

HEES OIL HEES ....................... Hydraulic Enviromental Ester Synthetic OIL HEES is a synthetic, biodegradeable oil intended for use in the hydraulic system only. Never use HEES in the: engine, transmission, axle, braking system or mix HEES with organic hydraulic oil.

Doing so could clog the hydraulic oil filter.

When switching to HEES for the hydraulic system: 1. Drain the organic oil from the tank completely. Disconnect the hydraulic lines and drain the oil from the lines and the cylinders.

2. Replace the hydraulic oil filter with a new one. Reconnect the hydraulic oil lines. Fill the hydraulic oil tank with HEES type oil.

3. Start the engine and let it idle until the hydraulic oil is 40°C. Operate all the work equipment to fill the hydraulic circuits. Stop the engine and check the hydraulic oil level.

Add oil as needed.

After completing the conversion to HEES, change the hydraulic oil after 1000 hours of operation. Thereafter, change the hydraulic oil every 2000 hours of operation.

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SAFETY CRITICAL PARTS Periodically some parts must be replaced due to safety purpose.

Even if these parts seem to be in good condition and operating properly they may fail at some point causing possible injury to the operator or pedestrian. Listed are some of the systems containing these components that may fail under extended use: •

Fuel supply and delivery hoses.

•

Hydraulic system: main delivery hoses and tubing.

•

Hydraulic hoses: all the hoses that feed and return the hydraulic fluid to and from the work equipment.

•

For additional information, see CRITICAL PARTS FOR SAFETY on page 3-14.

VIBRATIONS TO WHICH OPERATOR IS EXPOSED According to test results 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. The seated part of the body is subject to vibrations lower than 0.5 m/sq.

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2OPERATION

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2-1

OPERATION

GENERAL VIEW OF MACHINE The directions of left and right depend on whether the operator is using the loader or the backhoe. When operating the loader or traveling, the operator faces the front of the machine. When operating the backhoe, the operator faces the rear of the machine. Keep in mind that left and right change from front view to rear view.

FRONT VIEW OF MACHINE

B Front Bucket C Bucket Cylinder D Loader Boom

2-2

E Cab F Rear Axle G Fuel Tank

H Boom Cylinder I Front Axle

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OPERATION REAR VIEW OF MACHINE

b Bucket c Bucket Cylinder d Arm

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e Boom f Arm Cylinder g Boom Cylinder

h Hydraulic Oil Tank i Outriggers j Swing Cylinders

1) Boom Support Boss

2-3

OPERATION VIEW OF MACHINE CONTROLS - STANDARD

b c d e f g h i j 1) 1!

1@

Directional Lever Steering Wheel Front Dashboard Turn Signal Dimmer Switch Steering Wheel Adjustment Lock Loader Lever Accelerator Pedal Brake Pedals Side Dashboard Hand Accelerator Parking Brake Arm and Swing Lever ..................... ISO (Excavator) Controls Boom and Swing Lever ................... OPT (Backhoe) Controls

1# Boom and Bucket Lever ................. ISO (Excavator) Controls Arm and Bucket Lever .................... OPT (Backhoe) Controls

1$ Right Stabilizer Lever 1% Left Stabilizer Lever

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OPERATION VIEW OF MACHINE CONTROLS - PPC SYSTEM

b C D E F G h I J 1) 1!

1@

Directional Lever Steering Wheel Front Dashboard Direction Selector - Dimmer Switch Steering Wheel Adjustment Lock Loader Lever Accelerator Pedal Brake Pedals Side Dashboard Hand Accelerator Parking Brake Arm and Swing Lever ..................... ISO (Excavator) Controls Boom and Swing Lever ................... OPT (Backhoe) Controls

1# Boom and Bucket Lever ................. ISO (Excavator) Controls Arm and Bucket Lever ..................... OPT (Backhoe) Controls

1$ Left Outrigger Switch 1% Right Outrigger Switch

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OPERATION

MACHINE CONTROLS TRANSMISSION LEVER

Since no mechanical connection is provided between the gear shift and the engine, if the machine is parked on a slope it can move freely even with engaged gears; for this reason, always apply the parking brake, in order to avoid any damage. Disconnect the connector of the reversing gear, gear shift lever unit, before carrying out electric welding operations on the machine. Noncompliance with this rule may even result in deadly accidents, since the gear storage and the gear and direction selection microcircuits may be irreparably damaged.

Remark The engine can be started only with the gear shift lever in neutral position N. The selection of the reverse is signalled by an acoustic alarm positioned on the rear part of the frame.

Before reversing, make sure that the alarm functions properly by proceeding as follows: Start the engine, apply the pedal brake and shift the transmission lever to the reverse position REV. If the alarm does not work, have the machine checked by a distributor.

This is a combined controller that serves either to shift gears and/ or directions. The gears are engaged by means of the push buttons UP c and DOWN d, while the travelling direction is selected by means of the lever b.

The normal control of the gear shift is ensured by the semiautomatic system SA, with possibility to select the automatic system AU. This control is provided with a safety code to prevent theft.

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OPERATION MAIN FUNCTIONS OF THE CONTROLLER

b Reversing gear lever for the forward FWD, reverse REV and NEUTRAL N selection. c UP push button for the upshifting. d DOWN push button for the downshifting. e Red LED N: when this LED lights up, it indicates that the device preventing the accidental engagement of the FWD or REV is connected or that the reversing gear lever is not in NEUTRAL position during the start.

f Green LED FWD: when this LED lights up, it indicates that the forward gear has been selected. g Green LED REV: when this LED lights up, it indicates that the reverse gear has been selected. h 4WD push button for the engagement and disengagement of the four wheel drive in 1st or 2nd gear. i Green LED 4WD: when this LED is continuously on, it indicates that the 4WD push button is operating and the four wheel drive is engaged, when it is off, it indicates that the 4WD push button is not operating and the four wheel drive is disengaged and when it flashes, it indicates that the 4WD push button is operating and the four wheel drive has been temporarily disengaged in 3rd or 4th gear.

j Antitheft safety code push button for the connection or disconnection of this function. The connection is achieved by pressing the push button for more than 3 seconds with the engine running.

1) Green antitheft LED: when this LED lights up, it indicates that the antitheft function is in operation. When the engine is started again, it is necessary to enter the secret code to be able to move the machine.

1! Automatic logic connection push button AUT: the connection of the automatic logic AUT is possible only with

the engine running and the device preventing the accidental engagement in operation (red LED N on). The connection AUT is indicated by the coming on of two red points on the display 1%.

1@

DIM push button: this button confirms and acquires the antitheft code, regulates the luminous intensity of the

display and of the LEDs.

1# Orange configuration LED: it flashes when state changes are requested in a non optimal field.

1$ Red alarm LED: it is continuously on in case of serious faults associated with a figure code on the display; it flashes in case of slight faults associated with a figure code on the dispay.

1% Red luminous display: it indicates the automatic logic state, the engaged gear, the number relevant to the antitheft secret code, the state 88 after the energizing or the entry of a wrong antitheft code, the diagnostic references in case of anomaly in the transmission or in the electronic control system.

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OPERATION 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 and, after a quick self test, the 2nd gear with semiautomatic logic SA will be displayed 1%.

Remark If the engine is not started within 20 seconds, programmable, after turning the ignition key to position I, the electronic system inhibits the control and shows the figure code dP on the display 1%; turn the key to position O and repeat the starting procedure.

If the lever is not in the neutral position, the red LED N e comes on and the engine does not start. If the antitheft function has been connected before stopping the engine, after the self test it is necessary to enter the antitheft code.

SAFETY CODE PUSH BUTTON This function is connected by pressing the push button j once, LED 1) on, for at least 3 seconds before stopping the engine, this operation must be carried out by those who know the secret code. If the push button j is pressed more than once, the function is connected and disconnected in sequence, with the LED 1) coming on and going out alternately.

Remark After the engine start and the self test, if the anti theft function has been previously connected, LED 1) on, the secret code figures must be entered one by one using the UP and DOWN buttons, while the push button 1@ DIM must be used to confirm the entry.

After the entry of the correct secret code and the successive acoustic confirmation, the antitheft function is automatically excluded, LED 1) off; to connect this function again, press the push button j before stopping the engine.

The antitheft code is made up of 4 digits and is connected with the PN stamped on the casing. The digits are selected by means of the UP and DOWN buttons, 0 to 9 and each digit is confirmed with the button 1@ DIM. After the 4th digit has been confirmed, the electronic system acquires the code with 3 short beeps, 0.3 secs, and the 2nd gear with semiautomatic logic SA is displayed.

Remark If an INCORRECT digit is confirmed, 88 appears on the display and a long beep, 1 sec, is emitted; repeat the operation entering the right code. After five consecutive INCORRECT confirmations, stop the engine and start it again.

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OPERATION DIM PUSH BUTTON This push button confirms and acquires the antitheft code. The 4 digits of the secret code must be entered in sequence and each selection must be confirmed with the push button 1@ DIM. This button is used also to adjust the luminous intensity of the display 1% and of the LEDs, day/night, and this can be done after the engine start, the self test and the display of the 2nd gear.

4WD PUSH BUTTON This button engages the 4WD in 1st and 2nd gear with the green LED i on. If the 4WD is engaged in 3rd or 4th gear, the LED flashes and the function is inhibited. If you shift down from 3rd to 2nd gear with the button h on, the logic automatically recalls the 4WD function and the LED stops flashing and lights up continuously.

Remark In case of braking in 3rd or 4th gear, the logic automatically engages the 4WD and the green LED i lights up without flashing.

GEAR SHIFTING WITH SEMIAUTOMATIC LOGIC After the engine start, the self test and the entry and confirmation of the antitheft code, if any, the electronic control system always sets to the 2nd gear with semiautomatic logic SA. From the 2nd gear, with reversing gear in neutral position, it is possible to engage the 1st, 3rd or 4th gear by means of the buttons, c UP and d DOWN; engage the forward or reverse gear within 3 seconds after releasing the device that prevents the accidental selection of the FWD or REV gear.

Remark If the reversing gear lever is shifted to the neutral position N when the machine is moving, the electronic control system maintains the selected gear, 1st, 2nd, 3rd or 4th and shows it on the display. If the neutral N position is maintained for more than 3 seconds when the machine is not moving, the system signals an EMERGENCY; the electronic control system maintains the selected gear, see ACCIDENTAL PREVENTION SELECTION DEVICE on page 2-10.

If the gears are shifted at unsuitable speed, the flashing LED 1# comes on and this is signalled by a long beep, 1 sec. The electronic control system does not carry out the shifting, but stores the selection. When the optimal rpm has been reached, the flashing LED goes out and the selected gear is engaged. The electronic control system stores only one selection at a time.

The upshifting is carried out every 1.5 seconds without checking if the speed is optimal. If the UP or DOWN push buttons are pressed for more than 5 seconds, this is considered as a double selection. Pressure on the UP or DOWN push buttons for more than 0.25 seconds is considered a selection. The engaged gear is always shown on the display 1%. The 4th reverse gear is always disconnected.

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2-9

OPERATION ACCIDENTAL PREVENTION SELECTION DEVICE With the machine at rest and reverse gear lever in neutral position, after 3 seconds the system signals an emergency condition and the red warning light N e comes on. Press the UP or DOWN buttons again and start again within 3 seconds.

Remark After the engine start, during the self test and the entry of the antitheft code, if any, before the 2nd gear is displayed, if the reverse gear lever is accidentally set to the FWD or REV position, the logic automatically recalls the emergency function that prevents the accidental engagement from occurring again.

AUTOMATIC LOGIC PUSH BUTTON This function is connected by pressing the push button 1! AUT once, only with the machine at rest in safety condition, red LED N e on. The automatic function AU is indicated by the coming on of two red points on the display 1%. If the push button is pressed more than once, the function is connected and disconnected in sequence, with the two red points coming on and going out alternately on the display 1%.

GEAR SHIFTING WITH AUTOMATIC LOGIC After the connection of the automatic function AUT, button 1!, the electronic control system always sets on 2nd gear; engage the forward or reverse gear within the following three seconds.

It is possible to carry out the forced engagement of the 1st gear by means of the buttons DOWN d or KICK DOWN, checking the optimal rpm. After the forced engagement of the 1st forward or reverse gear, the AU logic will carry out the automatic shifting from 1st to 4th forward gear or from 1st to 3rd reverse gear, with successive automatic downshifting to the 2nd forward or reverse gear. The engaged gear is always shown on the display 1%. The 4th reverse gear is constantly disconnected.

Remark If the neutral N position is maintained for more than 3 seconds when the machine is not moving, the system signals an EMERGENCY; the electronic control system maintains the preselected gear, see ACCIDENTAL PREVENTION SELECTION DEVICE on page 2-10. Even the forced 1st gear remains preselected.

In case of damage to the solenoid valve of the 2nd or 3rd gear, signalled by 3 long beeps (1 sec) and by an intermittent figure code on the display 1%, the system passes directly from the automatic logic AU to the semiautomatic logic SA.

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OPERATION FWD/REV REVERSAL WITH LOGIC The FWD REV reversal is carried out in 1st and 2nd gear and must take place in the shortest possible time. The reversal is indicated by the coming on of the LED F f or R g. It is possible to stop in the neutral position N for a while.

When the reversal is requested in 3rd and 4th forward gear and the rpm is optimal, the control system immediately engages the 2nd gear with successive reversal. If the rpm is not optimal, the LED 1# starts flashing and this is signalled by a long beep (1 sec.).

The electronic control system does not carry out the reversal and the selection is stored. When the optimal rpm has been reached, the flashing LED goes out and the control system engages the 2nd gear with successive reversal.

With the SA logic, the UP DOWN button cannot be operated until reversal has been carried out. The electronic control system stores only one selection at a time.

Remark Reversals in 3rd and 4th gear can be carried out only in case of emergency.

KICK DOWN FUNCTION FOR 1ST AND 2ND GEAR ONLY A pulse push button b positioned on the loader control lever and connected to the electronic control system engages the 1st gear from the 2nd or the 2nd from the 1st and maintains the selected gear. With the semiautomatic logic SA, it is possible to shift from 1st to 2nd gear and from 2nd to 1st gear. With the automatic logic AU it is only possible to shift from 2nd to 1st gear.

If the KICK DOWN function is selected - 1st from 2nd gear - the electronic control system verifies the optimal rpm for the shifting, programmable.

When the rpm is not optimal, the flashing LED 1# comes on and a long beep (1 sec) is emitted. When the optimal rpm has been reached, the LED goes out and the 1st gear is engaged. If the KICK DOWN function is selected - 2nd from 1st gear - the engagement of the 2nd gear takes place immediately The functions of the UP DOWN button have priority over the functions of the KICK DOWN button. The electronic control system acquires a differentiated selection if between two selections a minimum time of 0.5 seconds elapses, the selections are not simultaneous.

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2-11

OPERATION DECLUTCH FUNCTION FOR THE 1ST AND 2ND GEAR ONLY A button c positioned on the loader control lever and connected to the electronic control system disconnects the transmission for the 1st and 2nd gear only.

The declutch function remains in operation as long as the button remains pressed.

Remark If the drive is re-connected with speed increasing the optimal rpm, the flashing LED 1# comes on, a long beep (1 sec) is emitted and the electronic control system engages the 3rd gear with semiautomatic logic.

DIAGNOSTIC FUNCTION FOR MACHINES NOT WORKING Condition either during self test and during operation.

D Red alarm LED 1$ permanently on D 3 long beeps (1 sec) D Figure message on the display 1% D All solenoid valves at rest This takes place due to high oil temperature, low pressure of the transmission oil, voltage below 7 volts, electronic card anomaly.

When a figure code appears on the display, contact your distributor for the necessary checks and repairs.

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OPERATION DIAGNOSTIC FUNCTION FOR MACHINES WORKING Condition during the self test.

D Red alarm LED 1$ flashing D 3 long beeps (1 sec) D Figure message on the display 1% Condition during operation.

D Red alarm LED 1$ flashing D 3 long beeps (1 sec) D Figure message flashing on the display 1% as an alternative to the indication of the engaged gear.

Remark In case of damage to the clutch filling pressure sensors, the system does not engage the gears corresponding to the damaged sensors. In case of damage to the clutch filling sensors of the 2nd and 3rd gear, the system passes automatically from the automatic logic AU to the semiautomatic logic SA. Engine start: In case of damage to the 2nd gear solenoid valve, the electronic control system takes the 1st gear as point of reference. In case of damage to the rpm sensor, the gear shifting with automatic logic AU does not take place any more.

When a figure code appears on the display, contact your distributor for the necessary checks and repairs.

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OPERATION FRONT INSTRUMENTS AND CONTROLS b c d e f g h i 1!

1) 1!

1@ 1# 1$ 1% 1^ 1&

Transmission Oil Temperature Light Engine Coolant Temperature Light Four Wheel Drive Warning Light Low Fuel Warning Light Direction Indicator Warning Light High Beam Warning Light Parking Brake and Brake Oil Level Light Optional Equipment Warning Light Multifunctional Switch Lever Four Wheel Drive Switch Front Windshield Wiper Washer Switch Front Working Light Switch Emergency Switch Hazard Optional Equipment Electric Safety Valve Switch Steering Push Button Unit Electronic Display

T RANSMISSION OIL TEMPERATURE ALERT This warning light b glows and an audible alarm sounds when the transmission oil overheats. If this light and alarm come on, immediately stop the machine and select neutral gear. Let the transmission oil cool down with the engine running at about 1200 rpm until the alarm stops. If the alarm and warning light come on frequently, have the machine checked by an authorized distributor. Do not continue to operate the machine.

ENGINE COOLANT TEMPERATURE ALERT This warning light c glows and an audible alarm sounds when the engine overheats. If this light and alarm come on, immediately stop the machine and select neutral gear. Let the engine run at about 1200 rpm until the alarm stops. If the engine continues to overheat, have the machine checked by your distributor.

FOUR WHEEL DRIVE INDICATOR When four wheel drive d is selected, this indicator light glows to indicate the four wheel drive system is engaged. When the indicator light is off, the four wheel drive system is disengaged.

LOW FUEL ALERT This warning light e comes on when there is about 17l of fuel left in the fuel tank. Refuel the machine as soon as possible. Avoid running the machine out of fuel. Damage to the fuel injectors may result when restarting the engine after the fuel runs out.

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OPERATION DIRECTIONAL SIGNAL INDICATOR A left or right turn indicator light f flashes when the multifunctional directional switch j is pushed up or down. Both the left and right turn indicator lights flash when the emergency/hazard switch 1# is engaged.

HIGH BEAM INDICATOR This indicator light g comes on when the high beam is actuated by the multifunctional switch lever j. When the switch lever is actuated again, the high beam is turned off.

PARKING BRAKE LOW BRAKE FLUID ALERT This warning lamp h indicates the parking brake is applied or the brake fluid level is low. This light should glow when the parking brake is set and go off after releasing the parking brake. If this warning lamp glows intermittently during operation or remains on after start up, do not operate the machine. Have the brake system checked by an authorized distributor.

OPTIONAL EQUIPMENT ALERT This location is for optional equipment indicator i.

MULTIFUNCTIONAL SWITCH LEVER This switch j controls five functions: 1. Left Turn Signal 2. Right Turn Signal 3. Horn 4. High Low Head Light Beams 5. Flash Head Lights FOUR WHEEL DRIVE SWITCH Pressing this switch 1) engages the four wheel drive and the indicator light d glows. When the switch is pressed again, the four wheel drive is disengaged and the indicator light d turns off.

However, the four wheel drive will automatically engage when the service brake pedals are pressed while in 4th gear. The combined action of automatically engaging the four wheel drive and applying the service brake reduces the stopping distance of the machine.

Remark Do not use the four wheel drive at high speeds or on dry roads.

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OPERATION WINDSHIELD WIPER/WASHER SWITCH This switch operates the front windshield wipers and washer 1!.

The first switch position operates the wipers. The second switch position operates the windshield washer.

FRONT WORK LAMPS SWITCH This switch 1@ operates the front work lamps only.

EMERGENCY HAZARD SWITCH Pressing this switch 1# causes both turn signals to flash simultaneously. This feature must be used when traveling on roadways or when working in areas that need additional warnings.

ELECTRIC SAFETY VALVE SWITCH Pressing this switch 1% deactivates the safety valves installed on the loader cylinders and a red LED turns on. Releasing this switch activates the safety valves and the red LED goes out. Turn off the electric safety valves before operating the load stabilizer system, LSS.

Always deactivate the electric safety valves when the load stabilizer system LSS is operated. For further information regarding the LSS, see LOAD STABILIZER SYSTEM (LSS) on page 5-33.

STEERING CONTROL PUSH BUTTON UNIT This is a control 1^ with microswitches in pairs, giving the opportunity to select from three different steering modes: A) Two Wheel Steering B) All Wheel Steering C) Crab Steering.

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OPERATION Steering Selector Unit Remark The selection of the crab steering must be carried out with the machine at rest and only in 1st and 2nd gear, while the selection of the all wheel steering can be performed even with the machine moving and only in 1st, 2nd and 3rd gear.

When the engine is started, the two wheel steering is automatically selected. If the acoustic alarm sounds when the machine is restarted, this means that the rear wheels are not aligned. The misalignment of the rear wheels is signalled also on the display 1& positioned of the front dashboard, through the alternate presence of the symbols and .

Turn the steering wheel clockwise or counterclockwise until the rear wheels are aligned, which is signalled by the coming on of the green warning light A and by the interruption of the alarm.

When the rear wheels are aligned, the symbols and disappear, while the speedometer, km/h or mph, is displayed again B. Every time a steering solenoid valve is powered, its correct operation is automatically tested: if there is a short circuit or an open circuit, a signal on the display 1& and the acoustic alarm inform the operator that there is a failure of the solenoid valve in question.

This is a control with coupled microswitches and is used to select the steering mode that is most suitable for the conditions of the ground and the type of work to be performed. The selection is obtained by pressing two coupled switches at the same time, with consequent coming on of the corresponding LED. This system makes it possible to switch over from crab steering to all wheel steering and vice versa, by pressing button b, which corresponds to the two wheel steering, and the button corresponding to the desired steering mode at the same time, button d for crab steering and button c for all wheel steering.

It is possible to switch over from crab or all wheel steering to two wheel steering by simply pressing button b, which corresponds to the two wheel steering C. The selected steering mode is activated only when the front and rear wheels are aligned, automatic wheel alignment.

If you switch over from one steering mode to the other while the wheels are being aligned, the acoustic alarm keeps sounding until the front or rear wheels are perfectly aligned.

The alignment of the wheels is indicated also on the display 1& positioned on the upper part of the front dashboard.

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OPERATION The display 1& indicates which wheels must be aligned through the relevant symbols: Front wheels misaligned...................................................... D Rear wheels misaligned ...................................................... E Once the wheels are aligned, the relevant symbols go out and the acoustic alarm stops.

Switching from Two Wheel Steering To All Wheel Steering Press buttons b and c at the same time and turn the steering wheel clockwise or counterclockwise 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.

The green LED X will go out and the red LED Z will come on at the same time. During the alignment phase the symbol will appear on the display 1& positioned on the front dashboard and will go out as soon as the front wheels are aligned. At this point the speedometer km/h or mph will appear on the display.

Remark The change from two wheel steering to all wheel steering is possible only in 1st, 2nd or 3rd gear, either with machine at rest or when the machine is moving, provided that the speed does not exceed 13 km/h, 8 mph.

Switching from Two Wheel Steering To Crab Steering Press buttons b and d at the same time and turn the steering wheel clockwise or counterclockwise 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. The green LED X will go out and the red LED Z will come on at the same time.

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OPERATION During the alignment phase the symbol will appear on the display 1& positioned on the front dashboard and will go out as soon as the front wheels are aligned. At this point the speedometer km/h or mph will appear on the display 1&.

Remark It is possible to switch over from two wheel steering to crab steering only in 1st or 2nd gear and with the machine at rest.

Switching From All Wheel Steering To Two Wheel Steering Press only button b and turn the steering wheel clockwise or counterclockwise 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.

The red LED Z will go out and the green LED X will come on at the same time. During the alignment phase the symbol will appear on the display 1& positioned on the front dashboard and will go out as soon as the rear wheels are aligned. At this point the speedometer km/h or mph will appear on the display.

Remark The change from all wheel steering to two wheel steering is possible either with machine at rest and when the machine is moving, provided that the speed does not exceed 13 km/h, 8 mph. For travelling on roads, use only the two wheel steering mode.

If during travel with two wheel steering the acoustic alarm sounds, this means that the rear wheels are misaligned. The misalignment of the rear wheels is signalled also on the display 1&, through the alternate presence of the symbols and , F. Stop the machine immediately and turn the steering wheel clockwise or counterclockwise until the rear wheels are aligned, which is signalled by the coming on of the green LED X and by the interruption of the acoustic alarm. In this case, the alignment of the rear axle can be carried out even if the machine is moving, provided that the speed does not exceed 13 km/h, 8 mph, and only after aligning the front axle.

Before leaving, make sure that the wheel misalignment symbols cannot be seen any longer on the display and that the speedometer (km/h or mph) is visible again.

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2-19

OPERATION Switching From All Wheel Steering To Crab Steering Press buttons b and d at the same time and turn the steering wheel clockwise or counterclockwise 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. The red LED X will go out and the red LED Y will come on at the same time. During the alignment phase the symbol will appear on the display 1& positioned on the front dashboard and will go out as soon as the rear wheels are aligned. At this point the speedometer will appear on the display 1&.

Remark It is possible to switch over from all wheel steering to crab steering only in 1st or 2nd gear and with the machine at rest.

Switching From Crab Steering To Two Wheel Steering Press only the button b and turn the steering wheel clockwise or counterclockwise 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.

The red LED Y will go out and the green LED Z will come on at the same time. During the alignment phase the symbol will appear on the display 1& positioned on the front dashboard and will go out as soon as the rear wheels are aligned.

At this point the speedometer km/h or mph will appear on the display 1&.

Remark It is possible to switch over from crab steering to two wheel steering with the machine either moving or at rest. For travelling on roads, use only the two wheel steering mode.

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OPERATION

If during travel with two wheel steering the acoustic alarm sounds, the rear wheels are misaligned. The misalignment of the rear wheels is signalled also on the display 1&, through the alternate presence of the symbols and , F. Stop the machine immediately and turn the steering wheel clockwise or counterclockwise until the rear wheels are aligned, which is signalled by the coming on of the green LED X and by the interruption of the acoustic alarm. Before leaving, make sure that the wheel misalignment symbols cannot be seen any longer on the display and that the speedometer (km/h or mph) is visible again.

Switching Over From Crab Steering To All Wheel Steering Press buttons b and c at the same time and turn the steering wheel clockwise or counterclockwise 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.

The red LED Y will go out and the red LED Z will come on at the same time. During the alignment phase the symbol will appear on the display 1& positioned on the front dashboard and will go out as soon as the rear wheels are aligned.

At this point the speedometer km/h or mph will appear on the display 1&.

Remark It is possible to switch over from crab steering to all wheel steering with the machine either moving or at rest. The 4th gear cannot be engaged with all wheel steering selected.

ELECTRONIC DISPLAY The electronic display 1& 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 mph; situation of the routine maintenance operations to be performed every 500, 1000 and 2000 hours; maintenance and emergency indicators; other messages.

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2-21

OPERATION After introducing the key and switching on the board, that is, making one click only with the key, in this phase the engine is off, it is possible to display all the following information in sequence, by pressing the CHECK button b only with the rear axle aligned.

Partial Service Hours Storage and display of the service hours between two successive maintenance operations. To set the number of service hours to zero, keep the SERVICE button c pressed for about 5 seconds.

The display 1& will show some symbols with the respective service hours, in the following order: Engine Oil. Engine Oil Filter.

Fuel Filter.

Air Cleaner.

Transmission Filter.

Brake Oil. Coolant.

Hydraulic Oil. Remark Set the service hours to zero only after performing the required maintenance operation.

Types of Oil Indication of the type of oil used in the machine, specifically for the following systems: Engine oil and transmission oil, A. Brake oil and hydraulic oil, B.

Maintenance Plan The display shows the maintenance plan in the following order: •

2-22

Maintenance operations to be performed every 500 hours, engine oil, fuel filter, air cleaner and engine oil filter.

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OPERATION •

Maintenance operations to be performed every 1000 hours, transmission filter.

•

Maintenance operations to be performed every 2000 hours, engine coolant, hydraulic oil and brake oil.

When a maintenance alarm is sent out, the display 1& keeps showing the speedometer together with the CHECK signal, A or B.

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OPERATION By pressing the CHECK button b, it is possible to display what maintenance operation must be performed.

If more than one maintenance operation must be performed at the same time, they can be displayed in sequence by pressing the SERVICE button c:

•

Every 500 hours: Engine oil................................................................ C Engine oil filter ........................................................ D

•

Every 500 hours: Fuel filter ................................................................. E Air cleaner .............................................................. F

•

Every 1000 hours: Transmission filter.................................................. G

•

Every 2000 hours: Brake oil................................................................. H

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OPERATION •

Every 2000 hours: Coolant ................................................................... J Hydraulic oil ........................................................... K

To return to the speedometer, press the CHECK button b again.

Once the required maintenance operation has been carried out, it is possible to reset the partial service hours for that specific maintenance operation, by showing the operation on the display 1& and keeping the SERVICE button c pressed for about 5 seconds.

The partial number of hours is thus cancelled and the count starts again, for each maintenance function, from the moment in which the reset of the alarm is carried out.

Remark Set the service hours to zero only after performing the required maintenance operation. The maintenance alarms must be accompanied by the flashing of the danger symbol.

Language Selection It is possible to display the list of all the languages available, in the following order: Italian English German French Spanish Portuguese Remark To select a language, move to the desired page by pressing the SERVICE button c.

Speed Indication Displays the machine speed during travel. According to the traffic rule in force, it is possible to choose from two units of measurement: ......................................................................... km/h or mph Remark To select one of the two units of measurement, move to the desired page by pressing the SERVICE button c.

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2-25

OPERATION Tire Pressure Display of the correct tire pressure for the front and rear tires. The pressure measured when checking the tires must correspond to that indicated on the display.

For further information on the tire pressure check, see TIRE PRESSURE on page 3-40.

Remark In this screen it is possible to select the tire size, by keeping the SERVICE button c pressed for about 10 seconds. The choice of the size depends on the type of tire with which the machine is provided.

The machine can be equipped with two types of tires: Standard tire ............................................................. 16.9 - 24 Optional tire .............................................................. 16.9 - 28 For the identification of the correct size, read the code on the tire outer sidewall. To carry out the selection, move to the desired page by pressing the SERVICE button c.

Operation Alarms Besides the functions described before, the display 1& 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 signal.

When the machine is started, while the steering system performs the tests on the solenoid valves, KOMATSU appears for a few seconds on the display 1&.

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OPERATION Successively, if no malfunction has been found, the speedometer appears on the display 1&, A or B.

If a malfunction should be found in the steering solenoid valves, the relevant message will appear on the display 1& and an acoustic signal will be sent forth, according to the solenoid valve presenting the failure. •

Crab steering solenoid valve failure.

•

All wheel steering solenoid valve failure.

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OPERATION •

Four wheel steering solenoid valve failure.

•

Two wheel steering solenoid valve failure.

•

Rear potentiometer failure

Other operation alarms that can be shown on the display 1&.

•

Alternator failure.

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OPERATION •

Insufficient engine oil pressure.

•

Maximum coolant temperature

•

Air cleaner clogging.

•

Converter oil maximum temperature.

When an operation alarm is emitted, stop the machine, engage all the safety locks and carry out the necessary repair.

The acoustic alarm has two different frequencies: higher frequency for the steering alarms and lower frequency for all the other alarms.

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OPERATION BRAKE PEDALS The machine is equipped with a tandem brake pedal d set up.

This set up makes it possible to separate the right and left braking system while making sharp turns.

During normal operation or when traveling on roads, the brake pedals d should be locked to allow for equal braking at each wheel.

When operating at slow speeds in tight locations, the brake pedals d can be separated to allow independent braking of the right or left side.

When operating with the brakes pedals unlocked, always operate at a slow speed, no higher than 1st gear. Never operate the machine at high speeds with the pedals unlocked. Always lock the brake pedals immediately after completing the operation. Failure to comply with this warning may result in serious injury.

ACCELERATOR PEDAL Use the accelerator pedal e for road travel or when using the loader. When using the loader and the accelerator pedal, be careful not to strain the machine. Always accelerate smoothly when using the loader.

LOADER LEVER

Before carrying out any operation with this lever, the operator 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. If it is necessary to leave the machine on a slope, take all the precautions aimed at preventing any uncontrolled movement of the machine itself. Before leaving the operator’s seat, lower the bucket to the ground and engage the safety lock before stopping the engine.

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OPERATION The front loader control lever f is positioned on the operator’s right and controls the raising and lowering of the arm and the folding and dumping of the bucket according to the orthogonal movements listed below.

If the machine is properly equipped, the shifting of the lever to position E, defined by a click, sets the loader to a free, or floating position, that is, to a position in which it can automatically follow the undulation of the ground.

Furthermore, when the lever f is shifted by 45° towards the axis of the machine in position F, the return to dig device is connected, which lowers the arm and at the same time moves the bucket back to loading position. As soon as the bucket touches the ground, the device is automatically disconnected and the machine returns to its normal position.

N - Neutral A - Bucket Roll B - Arm Lower C - Bucket Dump D - Arm Raise E - Arm Float F - Self Leveling - Return to Dig

If the lever is operated in directions that are inclined with respect to the machine axes, simultaneous movements proportional to the angle of inclination are obtained, since the two hydraulic distributors corresponding to each single function are engaged at the same time.

N - Neutral A - Arm Lower - Bucket Roll B - Arm Lower - Bucket Dump C - Arm Raise - Bucket Dump D - Arm Raise - Bucket Roll

Remark All the movements are locked when the safety pin is engaged. Always insert the safety pin when travelling on roads.

KICK DOWN Pressing this button g causes the transmission to downshift from 2nd gear to 1st gear.

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OPERATION PARKING BRAKE Before exiting the cab, apply the parking brake h. To set the parking brake, bring the machine to a full stop. Grasp the brake handle firmly and squeeze the lock lever below the brake handle.

Pull up on the handle until the brake handle locks in place. Release the lock lever. The brake light indicator will glow, indicating the parking brake is applied.

Remark Leaving the machine in gear with the engine off and the directional control set in the forward or reverse position WILL NOT HOLD THE MACHINE IN PLACE. Use the parking brake.

Always park the machine in neutral.

To release the parking brake, grasp the brake handle firmly. Pull the handle up slightly and squeeze the lock lever below the handle. Lower the handle down completely until it is fully released.

The brake light indicator will go off, releasing the parking brake.

Remark The rear wheel must be firmly on the ground in order for the parking brake to be effective. Always set the parking brake before exiting the cab.

HAND THROTTLE

The use of the hand throttle is allowed only under the conditions indicated; use in any other condition may cause serious accidents.

Use the hand throttle i when operating the backhoe or loader.

The throttle can also be used during engine warm up or during maintenance. The positions for the hand throttle are: Idle position: pull the lever backward.

Max speed position: push lever forward - 1900 to 2000 rpm.

If possible, avoid using the machine with the lever completely pushed forward, since in this way consumptions will be considerably reduced and the engine and machine life will be longer. For a correct use of the lever, keep to the indications given on the plate b applied inside the right dashboard. The plate is characterized by two colored areas, the green area A and the red area B, referring to different engine speeds: Green area A: this area indicates up to 1700 engine rpm, which is the value recommended to the operator.

Red area B: this area indicates up to 1900 Âą50 engine rpm, which is the maximum speed allowed for the use of the backhoe. The engine speed can be checked on the tachometer positioned on the side dashboard.

Remark Monitor throttle speed using the tachometer.

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OPERATION SIDE INSTRUMENTS AND CONTROLS - STANDARD b c d e f g h i 1!

1) 1!

1@ 1# 1$ 1% 1^ 1& 1* 1( 2) 2!

Fuel Level Indicator Tachometer Hourmeter Engine Coolant Temperature Indicator Air Cleaner Clogging Light Engine Oil Pressure Light Preheat Light Charging System Light Engine Coolant Temperature Light Optional Equipment Lights Acoustic Alarm Rear Working Light Switch Rear Windshield Wiper/Washer Switch Revolving Light Switch Rear Horn Switch Air Conditioner Switch Load Stabilizer System Switch Ignition Switch Fan Switch Backhoe Speed Control Button Backhoe Boom Lock Switch Optional Equipment Switch

FUEL LEVEL GAUGE This gauge b will indicate the amount of fuel in the fuel tank.

TACHOMETER AND HOURMETER This gauge c indicates the engine rpm. The gauge also indicates the number of hours the engine has been running.

Remark The hourmeter is used to determine the maintenance intervals for the machine.

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OPERATION ENGINE COOLANT TEMPERATURE GAUGE This gauge d indicates the engine coolant temperature. The operating range is from 80 to 85° C. Always allow the engine ample time to warm up to within the operating range before working the machine. Never allow the engine to exceed the operating temperature, or engine damage could occur.

AIR CLEANER RESTRICTION ALERT This warning light e comes on when the engine air filter is restricted. If this light comes on during operation, shut the machine down and replace the air filter. Do not operate the machine with a restricted air filtering system, or engine damage may result.

ENGINE OIL PRESSURE ALERT This warning lamp f comes on in addition to an audible alarm sounding to alert the operator of an engine oil pressure loss. Turn off the engine immediately and have the system checked by your distributor if this light: Comes on or comes on intermittently during operation.

Remains on after start up.

Does not come on when the ignition key is turned to the on position.

PREHEAT INDICATOR The light g comes on when the ignition key is turned to the preheat position for the cold start of the engine, see COLD WEATHER on page 2-81.

Do NOT use ether to assist in cold weather starting because of the preheater. Damage to the engine and injury to the operator may result.

ALTERNATOR ALERT This warning light h comes on in addition to an audible alarm sounding to alert the operator that the battery is not charging. If this light does NOT come on when the ignition switch is turned to the I position, or comes on during operation or remains on after start up, have an authorized distributor check the charging system.

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OPERATION ENGINE COOLANT TEMPERATURE ALERT This warning light i glows and an audible alarm sounds when the engine overheats. If this light and alarm come on, immediately stop the machine and select neutral gear. Let the engine run at about 1200 rpm until the warning and alarm stop. If this condition should occur again, check to make sure the radiator fins are clean and free of debris. Do not continue to operate the machine if the engine is overheating.

OPTIONAL EQUIPMENT ALERT This location is for any optional equipment warning indicators j.

AUDIBLE WARNING SYSTEM When the machine is in operation, the audible alarm 1) will sound, if the: •

Engine oil pressure is low.

•

Engine is overheating.

•

Transmission is overheating.

•

Charging system has failed.

REAR WORK LAMPS This switch 1! operates the rear work lamps. Turn off the work lamps when traveling on the road.

REAR WINDSHIELD WIPER/WASHER SWITCH This switch 1@ operates the rear windshield wipers and washer.

The first position on the switch operates the wipers. The second position operates the washer.

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OPERATION EMERGENCY FLASHING LIGHT SWITCH This switch 1# operates the rotating or flashing light mounted on top of the ROPS.

REAR HORN This switch 1$ activates the rear horn. This horn is to warn people in the area before you start work operations.

LOAD STABILIZER SWITCH Pressing this switch 1% turns on the load stabilizing system (LSS).

This feature helps stabilize the machine when the loader is full and traveling on rough ground.

Remark Turn off the electric safety valves before operating the load stabilizer system (LSS).

AIR CONDITIONING SWITCH Pressing this switch 1^ turns on the air conditioning system, and a green LED comes on. When the switch is off, the air conditioning system is deactivated.

IGNITION SWITCH The four positions of the ignition switch 1&: •

Preheat

•

OFF

•

ON

•

Start

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OPERATION BLOWER SWITCH The blower switch 1* controls the blower motor operation, which has three speeds: •

Low

•

Medium

•

High

The temperature switch T adjusts the temperature of the airflow delivered inside the cab. Turning the knob clockwise increases the air temperature while turning the knob counterclockwise decreases the air temperature. The recirculation switch R blocks outside air from entering the cab, causing the air within the cab to recirculate. Use the recirculation feature in extreme hot or cold weather, and when working in dusty areas. Using different combinations of fan speed, temperature setting, and recirculation obtains the desired temperature within the cab.

BACKHOE POWER CONTROL SWITCH This button 1( operates the selection of oil delivery from the hydraulic pump. Starting the machine automatically selects the POWER (switch illuminated), providing maximum power. Operating the machine in the forward or reverse gear automatically cancels the POWER mode. To return to the POWER mode, shift the gear lever to the neutral position.

Pressing the button, the backhoe goes into the economy mode, reducing power. This feature is used for excavating light material, operating optional attachments or using the backhoe for grading purpose.

BACKHOE BOOM LOCK SWITCH This button 2) operates the boom lock. This function holds the backhoe in the parked position, preventing hydraulic drift of the backhoe unit. Use this feature when using the loader or traveling with the machine.

OPTIONAL SWITCH LOCATIONS This switch location 2! is for optional equipment.

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OPERATION SIDE INSTRUMENTS AND CONTROLS - PPC SYSTEM

B C D E F G H I J 1) 1!

1@

Fuel Level Indicator Tachometer - Hour Meter Engine Coolant Temperature Indicator Air Cleaner Indicator Warning Light Engine Oil Pressure Warning Light Intake Air Preheating Warning Light Alternator Warning Light Engine Coolant Temperature Warning Light Optional Equipment Warning Lights Audible Alarm Rear Work Light Switch

1# 1$ 1% 1^ 1& 1* 1( 2) 2@ 2# 2$

Beacon Light Switch Rear Horn Air Conditioner Switch Load Stabilizer System Switch Ignition Switch Fan Switch Backhoe Control Switch Backhoe Boom Lock Switch Backhoe Lock Out Switch Left Outrigger Control Switch Right Outrigger Control Switch

Rear Wiper Washer Switch

FUEL LEVEL GAUGE This gauge b will indicate the amount of fuel in the fuel tank.

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OPERATION TACHOMETER AND HOUR METER This gauge c indicates the engine rpm. The gauge also indicates the number of hours the engine has been running.

Remark The hour meter is used to determine the maintenance intervals for the machine.

ENGINE COOLANT TEMPERATURE GAUGE This gauge d indicates the engine coolant temperature. The operating range is from 80 to 85° C. Always allow the engine ample time to warm up to within the operating range before working the machine. Never allow the engine to exceed the operating temperature, or engine damage could occur.

AIR CLEANER RESTRICTION ALERT This warning light e comes on when the engine air filter is restricted. If this light comes on during operation, shut the machine down and replace the air filter. Do not operate the machine with a restricted air filtering system, or engine damage may result.

ENGINE OIL PRESSURE ALERT This warning lamp f comes on in addition to an audible alarm sounding to alert the operator of an engine oil pressure loss. Turn off the engine immediately and have the system checked by your distributor if this light: •

Comes on or comes on intermittently during operation.

•

Remains on after start up.

•

Does not come on when the ignition key is turned to the on position.

PREHEAT INDICATOR The light g comes on when the ignition key is turned to this position for the cold start of the engine, see COLD WEATHER on page 2-81.

Do NOT use ether to assist in cold weather starting because of the air intake heater. Damage to the engine and injury to the operator may result.

ALTERNATOR ALERT This warning light h comes on in addition to an audible alarm sounding to alert the operator that the battery is not charging. If this light does NOT comes on when the ignition switch is turned to the IGN position, or comes on during operation or remains on after start up, have an your distributor check the charging system.

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OPERATION ENGINE COOLANT TEMPERATURE ALERT This warning light i glows and an audible alarm sounds when the engine overheats. If this light and alarm come on, immediately stop the machine and select neutral gear. Let the engine run at about 1200 rpm until the warning and alarm stop. If this condition should occur again, check to make sure the radiator fins ar clean and free of debris. Do not continue to operate the machine if the engine is overheating.

OPTIONAL EQUIPMENT ALERT These three locations are for any optional equipment warning indicator j.

AUDIBLE WARNING SYSTEM When the machine is in operation, the audible alarm 1) will sound, if the: •

Engine oil pressure is low.

•

Engine is overheating.

•

Transmission is overheating.

•

Charging system has failed.

REAR WORK LAMPS This switch 1! operates the rear work lamps. Turn off the work lamps when traveling on the road.

REAR WINDSHIELD WIPER/WASHER SWITCH This switch 1@ operates the rear windshield wipers and washer.

The first position on the switch operates the wipers. The second position operates the washer.

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OPERATION EMERGENCY FLASHING LIGHT SWITCH This switch 1# operates the rotating or flashing light mounted on top of the ROPS.

REAR HORN This switch 1$ activates the rear horn. This horn is to warn people in the area before you starting work operations.

LOAD STABILIZER SWITCH Pressing this switch 1% turns on the load stabilizing system (LSS).

This feature helps stabilize the machine when the loader is full and traveling on rough ground.

Remark Turn off the electric safety valves before operating the load stabilizer system (LSS).

AIR CONDITIONING SWITCH Pressing this switch 1^ turns on the air conditioning system, and a green LED comes on. When the switch is off, the air conditioning system is deactivated.

IGNITION SWITCH The four positions of the ignition switch 1&: •

Preheat

•

OFF

•

ON

•

Start

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OPERATION BLOWER SWITCH The blower switch 1* controls the blower motor operation, which has three speeds: • • •

Low Medium High

The temperature switch T adjusts the temperature of the airflow delivered inside the cab. Turning the knob clockwise increases the air temperature while turning the knob counterclockwise decreases the air temperature. The recirculation switch R blocks outside air from entering the cab, causing the air within the cab to recirculate. Use the recirculation feature in extreme hot or cold weather, and when working in dusty areas. Using different combinations of fan speed, temperature setting, and recirculation obtains the desired temperature within the cab.

BACKHOE CONTROL SWITCH This switch 1( permits the selection of the oil delivery of the hydraulic pump. When restarted, the machine automatically selects the POWER mode (LED on), even if it was stopped and the selected mode was ECONOMY. This position makes it possible to use the maximum oil delivery and is indispensable for the correct use of the backhoe. When the switch is pressed (LED off), the ECONOMY operation mode is selected. To return to the POWER mode (LED on), press the switch again. The machine passes automatically from the POWER to the ECONOMY operation mode when the forward or reverse gear is engaged. To return to the POWER operation mode, shift the lever back to the neutral position BACKHOE BOOM LOCK SWITCH This switch 2) is used to couple the safety lock with the boom when the backhoe is not used or when travelling. The safety lock is engaged when the switch is off (LED off), while its disengagement takes place when the switch is on (LED on). The function of the switch cannot be disabled through the lock out switch 2@.

LOCK OUT SWITCH This switch 2@ has the specific function to disable all the backhoe controls. This function must always be activated when the backhoe is not used or when travelling on roads. To activate the locking function, press the lock out switch. Locking of the controls is indicated by the illumination of the switch light. To deactivate, press the lock out switch again and the switch light will go out.

The backhoe locking function is automatically activated at each start of the machine and is signalled by the coming on of the illumination of the switch light.

LEFT OUTRIGGER CONTROL SWITCH This switch 2# controls the lifting and lowering of the left outrigger.

Push the switch towards the outside of the cab to lower the left outrigger. To lift the outrigger, pull/push the switch towards the inside of the cab. The function of the switch can be disabled by means of the lock out switch 2@.

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OPERATION RIGHT OUTRIGGER CONTROL SWITCH This switch 2$ controls the lifting and lowering of the right outrigger. Push the switch towards the outside of the cab to lower the right outrigger. To lift the outrigger, pull/push the switch towards the inside of the cab. The function of the switch can be disabled by means of the lock out switch 2@.

LOADER LEVER BUTTONS LOADER SPEED CONTROL The use of the push button 1) makes it possible to utilize the maximum oil delivery from the hydraulic pump when the machine is under load. Press the push button to increase the delivery; when the push button is released, the oil delivery returns to the standard operating values.

Remark It is advisable to use the push button without interruption for no more than 5 to 6 seconds.

DECLUTCH PUSH BUTTON Pressing this button 1! transfers all engine power from the drive line to the loader hydraulics when lifting heavy loads. This feature should only be used on level ground.

Do not press this button for more than 15 to 20 seconds. Do not press this button when traveling or operating on an incline or loss of control may result.

BUCKET OPEN Pressing this button 1@ opens the top half of the bucket, when released the bucket half stops. This action converts the bucket into a dozer blade or to use the bucket for picking up items.

FRONT OPTIONAL EQUIPMENT This button 1@ allows a 75l/min flow for front mounted optional equipment at the right side of the loader boom.

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OPERATION BUCKET CLOSE Pressing this button 1# closes the top half of the bucket, allowing the operator to use the bucket for dig and load operations.

FRONT OPTIONAL EQUIPMENT This button 1# allows a 75l/min flow for front mounted optional equipment at the left side of the loader boom.

BACKHOE CONTROLS - STANDARD

Before carrying out any maneuver 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; before any maneuver, take all the precautions indicated, see USING THE BACKHOE on page 298. DO NOT carry out any movement with the machine while working with the backhoe equipment or in any case with the seat rotated by 180° with respect to the regular driving position. Remember that the operator must carry out any movement of the machine while seated in the correct driving position, with locked seat and fastened safety belt. Before leaving the working position, lower the equipment to the ground and do not stop the engine if the safety lock is not engaged. When travelling on roads, always lock the levers with the safety lock.

The backhoe control levers can be equipped with different boom, arm, and bucket controls according to two different systems: ISO CONTROLS ........................................... Excavator Style OPT CONTROLS ............................................ Backhoe Style No movement can be carried out when the safety lever is shifted upwards. The following diagrams show the basic and combined maneuvers that can be performed with these systems.

ISO CONTROLS - EXCAVATOR STYLE Right Lever 1$ Basic Maneuvers N - Neutral A - Boom swing left B - Arm extend C - Boom swing right D - Arm retract

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OPERATION Left Lever 1% Basic Maneuvers N - Neutral A - Bucket roll B - Boom lower C - Bucket open D - Boom raise

If the levers are operated in directions that are inclined with respect to the machine axis, simultaneous movements proportional to the angle of inclination are obtained, since the two hydraulic distributors corresponding to each single function are engaged at the same time.

Right Lever 1$ Combined Maneuvers N - Neutral A - Arm extend - Boom swing left B - Arm extend - Boom swing right C - Arm retract - Boom swing right D - Arm retract - Boom swing left

Left Lever 1% Combined Maneuvers N - Neutral A - Boom lower - Bucket roll B - Boom lower - Bucket dump C - Boom raise - Bucket roll D - Boom raise - Bucket dump

OPT CONTROLS - BACKHOE STYLE Right Lever 1$ Basic Maneuvers N - Neutral A - Boom swing left B - Boom lower C - Boom swing right D - Boom raise

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OPERATION Right Lever 1% Basic Maneuvers N - Neutral A - Bucket roll B - Arm extend C - Bucket dump D - Arm retract

If the levers are operated in directions that are inclined with respect to the machine axis, simultaneous movements proportional to the angle of inclination are obtained, since the two hydraulic distributors corresponding to each single function are engaged at the same time.Right Lever 1$ Combined Maneuvers N - Neutral A - Boom lower and swing left B - Boom lower and swing right C - Boom raise and swing right D - Boom raise and swing left

Left Lever 1% Combined Maneuvers N - Neutral A - Arm extend - bucket roll B - Arm extend - bucket open C - Arm retract - bucket open D - Arm retract - bucket roll

STABILIZER CONTROL LEVERS

Before moving the machine, make sure that the outriggers are completely raised. When travelling on roads, raise the outriggers completely and engage the safety locks

These levers control the lowering and raising of the machine stabilizers during digging operations.

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OPERATION BACKHOE CONTROLS - PPC SYSTEM

1@ Left Joystick Lever 1# Right Joystick Lever b c d e f g h i j 1) 1!

1$ 1% 1^

Left Joystick Lock Lever Right Joystick Lock Lever Left Support Adjusting Knob Right Support Adjusting Knob Left Joystick Stroke Adjusting Knob Right Joystick Stroke Adjusting Knob Horn Push Button Telescopic Arm Retraction Push Button Telescopic Arm Extension Push Button Hammer Push Button Pattern Change Valve Lever Backhoe Lock Out Switch Arm Off Set Left Switch Arm Off Set Right Switch

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OPERATION PPC LEVERS

Before carrying out any maneuvers with these levers, the operator must be sitting in the working position, that is, with the seat rotated 180° with respect to the driving position and with fastened safety belt; before any maneuver, take all the precautions. DO NOT carry out any movement with the machine while working with the backhoe equipment or in any case with the seat rotated to the regular driving position. Remember that the operator must carry out any movement of the machine while seated in the correct driving position, with locked seat and fastened safety belt. Before leaving the drivers seat, lower the equipment to the ground, always engage the safety device to lock the backhoe controls by pressing the lock out switch 1$ and raise both joysticks 1@ and 1# towards the rear of the machine. Before starting to use the controls, check the control pattern by carrying out short maneuvers in order to make sure the all the movements corresponds to those shown on the decals. When travelling on roads, always engage the lock out switch 1$ to lock the backhoe controls.

This feature is particularly useful, less effort is required to move the controls and this reduces the stress to which the operator is subjected, as well as the time required to carry out the various operations. All backhoe controls can be disabled by pressing the lock out switch 1$ positioned on the side dashboard.

The locking of the controls is confirmed by the illumination of the switch light. To enable the backhoe controls, press the lock out switch 1$ again until the switch light goes out.

To use the backhoe control levers correctly, proceed as follows: 1. With the machine at rest and the engine off, sit in the driver’s seat and rotate it by 180° with respect to the driving position.

2. Press the joystick lock levers b and c and lower both joysticks 1@ and 1# until they reach the desired operating position. Once they have reached the desired position, release both the lock levers in order to lock the joysticks.

The position of the joysticks in operating conditions can be adjusted by means of the relevant knobs f and g positioned on the cab floor.

3. Adjust the height of the supports A by means of the adjusting knobs d and e, until finding the position that is most suitable to your physical characteristics.

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OPERATION 4. Once the correct operating position of both joysticks has been found, fasten the safety belt and start the machine.

Disengage the backhoe locking device by pressing the lock out switch 1$. The controls are released when the relevant warning light goes out.

5. At the end of work, lower the equipment to the ground and engage the locking device by pressing the lock out switch 1$ again. The controls are locked when the relevant warning light goes on.

6. Before rotating the seat to the driving position, press the levers b and c and at the same time raise the joysticks 1@ and 1# to bring them in vertical position. Once the desired position has been reached, release the levers to lock the joysticks, respecting a given safety distance from the rear window. If it is necessary to adjust the stroke of both joysticks, turn the adjusting screws positioned on the front part of the same.

The control lever 1@ is positioned on the operators left and controls the arm and the swing, while the control lever 1# positioned on the operators right controls the boom and the bucket. The machine is equipped with two different control patterns at the same time, more precisely: ISO CONTROLS ............................................Excavator Style OPT CONTROLS .............................................Backhoe Style The choice of the desired control pattern is up to the operator; for the selection of the pattern desired.

OUTRIGGER SWITCHES

Before moving the machine, make sure that the outriggers are completely raised. When travelling on roads, raise the outriggers completely and engage the safety locks. Engage the boom locking device by pressing the lock out switch j.

These switches are positioned on the upper part of the side dashboard and control the lowering and lifting of the machine outriggers during digging operations.

Push the switches 1& and 1* towards the outside in order to lower both outriggers. To lift them, pull/push the switches and towards the inside of the cab.

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OPERATION Both switches can be disabled by means of the lock out switch 1$.

ISO CONTROLS - EXCAVATOR sTYLE The following diagrams show the basic and combined maneuvers that can be performed with these systems.

Lever 12 Basic Maneuvers N - Neutral A - Boom swing left B - Arm extend C - Boom swing right D - Arm retract

Lever 13 Basic Maneuvers N - Neutral A - Bucket roll B - Boom lower C - Bucket open D - Boom raise

If the levers are operated in directions that are inclined with respect to the machine axis, simultaneous movements proportional to the angle of inclination are obtained, since the two hydraulic distributors corresponding to each single function are engaged at the same time.

Lever 12 Combined Maneuvers N - Neutral A - Arm extend - Boom swing left B - Arm extend - Boom swing right C - Arm retract - Boom swing right D - Arm retract - Boom swing left

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OPERATION Lever 13 Combined Maneuvers N - Neutral A - Boom lower - Bucket roll B - Boom lower - Bucket dump C - Boom raise - Bucket roll D - Boom raise - Bucket dump

OPT CONTROLS - BACKHOE STYLE The following diagrams show the basic and combined maneuvers that can be performed with these systems.

Lever 16 Basic Maneuvers N - Neutral A - Boom swing left B - Boom lower C - Boom swing right D - Boom raise

Lever 17 Basic Maneuvers N - Neutral A - Bucket roll B - Arm extend C - Bucket dump D - Arm retract

If the levers are operated in directions that are inclined with respect to the machine axis, simultaneous movements proportional to the angle of inclination are obtained, since the two hydraulic distributors corresponding to each single function are engaged at the same time.

Lever 16 Combined Maneuvers N - Neutral A - Boom lower and swing left B - Boom lower and swing right C - Boom raise and swing right D - Boom raise and swing left

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OPERATION Lever 17 Combined Maneuvers N - Neutral A - Arm extend - bucket roll B - Arm extend - bucket open C - Arm retract - bucket open D - Arm retract - bucket roll

JOYSTICK LOCK LEVERS

The operator must use the joystick locking levers while seated with the machine at rest. Before using these levers, always make sure that the backhoe locking switch is engaged.

These levers are positioned under the supports and their function is to lock or release the respective joysticks. It is possible to move both joysticks to the desired operating position by pressing the levers b and c. Once the desired position has been reached, release the levers to lock the joysticks.

At the end of the digging operation, always bring the joysticks back to the vertical position.

SUPPORT ADJUSTING KNOB

The operator must adjust the supports while seated in the driving position, before starting work and with the machine completely still. Before adjusting these knobs, always be sure that the boom locking device is engaged.

These knobs make it possible to position the corresponding supports A at the desired height. To release and adjust the supports, it is sufficient to turn both the knobs d and e anticlockwise, as indicated by the arrow B. Once the supports have been positioned as desired, turn the knobs clockwise until locking them, as indicated by the arrow C. After carrying out the adjustment, make sure that the knobs d and e and the supports A are locked.

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OPERATION JOYSTICK STROKE ADJUSTING KNOB

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 back hoe lock switch is engaged.

These knobs are positioned on the cab floor, on the front part of each joystick support, respectively. Their specific function is to adjust the stroke of both joysticks in order to reach the most suitable operating position; for the adjustment, proceed as follows: 1. After releasing the joysticks, lower them completely until reaching the end of stroke. If they are excessively inclined, reduce the stroke by turning the knobs f and g clockwise, as indicated by arrow A. If it is necessary to increase the stroke in order to obtain a more inclined position of the joysticks, turn the knobs counterclockwise, as indicated by arrow B. 2. After adjusting both joysticks, make sure that their position is within the desired values. It is possible to adjust the stroke of the joysticks when these are not used and are brought to the vertical position. Once they have been lifted, make sure that the safety distance between the joystick c and the rear window d is such as to prevent any contact between them (approximately 60 mm).

If an adjustment should be necessary, proceed as follows: 1. To increase the distance between the joystick 1& and the rear window 1*, loosen the stop nut 1( from its terminal position and turn the adjusting 2) screw clockwise. To reduce the distance between the joystick and the rear window, turn the adjusting screw counterclockwise.

2. Make sure that the distance complies with the safety limits prescribed and tighten the stop nut 1(.

After adjusting the stroke of both joysticks, make sure that all the fastening elements are correctly locked.

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OPERATION HORN BUTTON This push button h is positioned on the left backhoe control lever and serves to warn people in the vicinity at the beginning of the operations and in case of danger when working with the backhoe.

When the lock out switch 1$ is engaged, the function of the horn is inhibited.

TELESCOPIC ARM BUTTONS Arm Retracted This is a single function push button positioned on the right joystick lever and controls the retraction of the telescopic arm. To retract the arm, press the push button i; to stop the arm, release the push button.

When the lock out switch 1$ is engaged, the function of the telescopic arm is inhibited.

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OPERATION ARM EXTENDED This is a single function push button positioned on the right joystick lever and controls the extension of the telescopic arm. To extend the arm, press the push button 3!; to stop the arm, release the push button.

When the lock out switch 1$ is engaged, the function of the telescopic arm is inhibited.

HAMMER BUTTON To operate the hammer, press down on the switch 1); to stop the hammer, release the switch.

When the lock out switch 1$ is engaged, the function of the hammer is inhibited.

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OPERATION PATTERN CHANGE LEVER

The desired pattern must be selected before starting work, with the machine completely still. Before using the controls, the operator must make sure that the selected pattern is the one required. The operator must also make sure that the lever 1! is perfectly locked.

The pattern change lever 1! is positioned on the rear central part of the cab floor, under the decal 2!, below the floor mat. This lever allows the operator to choose the control pattern preferred. The pattern change lever has two positions: Position 1

ISO Excavator Pattern ....................... Position A.

Position 2

OPT Backhoe Pattern ........................ Position B.

The pattern change lever 1! is held in its position by means of a safety screw 2@. When it is necessary to change the control pattern, raise the mat and loosen the safety screw until it releases the lever completely.

Select the desired control pattern by rotating the lever horizontally and secure it in its position by means of the safety screw.

Put back the mat.

When the lock out switch 1$ is engaged, all the movements of the boom, the arm and the equipment are inhibited.

Before using the controls, the operator must make sure that the control system selected with the lever 1! corresponds to the control pattern shown opposite the respective joysticks.

To select the desired control pattern, turn the corresponding plates 2# and 2$ 180°. To check what control patterns are available, see the following.

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OPERATION

OFFSET BOOM LEFT BUTTONS Left Button This is a single function button positioned on the left joystick lever and allows the arm to be swung to the left offset of the boom. To swing the arm, press the button 1%; to stop the arm, release the button. For the use of the offset boom, see OFFSET BOOM on page 5-25.

When the control safety device 1$ is engaged, all the movements are inhibited.

The button 1% can be used also for other optional equipment as an alternative to the offset boom.

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OPERATION Right Button This is a single function button positioned on the left joystick lever and allows the arm to be swung to the right offset of the boom. To swing the arm, press the button 1^; to stop the arm, release the button. For the use of the offset boom, see OFFSET BOOM on page 5-25.

When the control safety device 1$ is engaged, all the movements are inhibited.

The button 1^ can be used also for other optional equipment as an alternative to the offset boom.

BACKHOE BOOM LOCK CONTROL

Always engage the boom safety lock when the backhoe is not used and when travelling on roads.

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 by means of a pin.

To lock the boom, proceed as follows: 1. Fold the bucket and arm completely. Raise the safety lock b by pressing the control switch d, LED on, positioned on the side dashboard.

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OPERATION 2. Raise the boom completely and engage the safety lock b by pressing the switch d again, LED off.

3. Insert the antirotation pin c.

STEERING WHEEL LOCK LEVER

Adjust the steering wheel while seated in the driving position. The machine must be completely still and the engine must be off. Before using the machine, make sure that both the steering wheel and the adjusting lever are completely locked. Noncompliance with these instructions may lead to serious accidents.

This lever b is located on the left side of the steering wheel and allows the wheel to be adjusted according to the physical characteristics of the operator.

It is possible to choose among different positions; for the adjustment, proceed as follows: 1. After stopping the machine and the engine, turn the lever b counterclockwise to release the steering wheel.

2. Adjust the steering wheel by moving it forward and backward until finding the desired position. Turn the lever b clockwise to lock the steering wheel in the desired position.

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OPERATION If the stroke of the lever b isn’t sufficient to lock the steering wheel completely, pull out the lever. At this point, shift the lever to its original position by repeating the operation and turning it clockwise or counterclockwise.

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OPERATION

ELECTRICAL ACCESSORIES OVERHEAD LAMP The overhead lamp b is used to check the instruments and the inside of the cab when visibility is scarce.

ELECTRIC OUTLET The electric outlet c is a 12V outlet in compliance with the ISO standards. It is used for the connection of the revolving light and of the inspection lamp when maintenance operations are to be carried out and visibility is scarce and for the connection of the emergency light. The outlet is powered with the revolving light switch.

12V SUPPLY OUTLET The outlet d is positioned on the lower part of the side dashboard and is powered by a 12V supply. It is used for the insertion of the cigarette lighter and is perfectly compatible with lighters available on the market. The same outlet can also be used to recharge mobile phones; before using it, remove the safety plug A.

BATTERY DISCONNECTION SWITCH The battery disconnection switch e is positioned on the left side of the machine, inside the engine compartment. To reach it, it is necessary to open the engine hood. It is possible to interrupt the passage of current from the battery to the electric system of the machine by rotating the switch counterclockwise and removing it.

Always interrupt the passage of current before carrying out any operation on the battery or the electric system and before carrying out any welding operation on the machine. To restore the electric contact, put back the switch and rotate it clockwise.

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OPERATION FUSES AND RELAYS - A90002 TO A90008

When changing a fuse, make sure that the ignition switch is in the OFF 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. If the engine does not turn when the ignition switch is turned to START, check the engine start fuse and change if necessary.

EQUIPMENT FUSES AND RELAYS The fuses and relays are grouped on a single base positioned inside the front dashboard and protected by a access door b.

The following tables indicate the characteristics and the functions of the single fuses and relays.

Fuses POSITION

COLOR

AMPS

INVOLVED CIRCUIT

F1

A B C

Light blue Violet Violet

15 3 3

Low beam Rear right and front left parking light Rear left and front right parking light

F2

A B C

Red Brown Red

10 7.5 10

Electric lighter Cab dome light - Radio Emergency power supply

F3

A B C

Brown Brown Brown

7.5 7.5 7.5

Start enabling Instruments - Switch lights OPT Solenoid valve

F4

A B C

Brown Red Light Blue

7.5 10 15

Differential lock solenoid valve Direction selector High beam

F5

A B C

Light blue Light blue Light blue

15 15 15

Heater Rear working light Front working light

F6

A B C

Light blue Brown Red

15 7.5 10

Windshield wiper - Revolving beacon Dimmer switch - Horn relay Direction indicators

F7

A B C

Brown Red Brown

7.5 10 7.5

Monitor Horn Alternator excitation - Engine stop solenoid

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OPERATION

Relays POSITION

DESCRIPTION

K1

Forward gear relay

K2

Reversing gear relay

K3

Four wheel drive relay

K4

---

K5

Low beam relay

K6

High beam relay

K7

Direction selector power supply relay

K8

Horn relay

K9

Blinker relay

K10

Flasher

K11

4th gear signaling relay

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OPERATION ENGINE FUSES AND RELAYS The fuses and relays are grouped on a single base positioned inside the engine compartment and are protected by a cover b.

This unit can be reached by opening the engine hood, see ENGINE HOOD on page 2-71.

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OPERATION Fuses POSITION

AMPS

COLOR

DESCRIPTION

F1

White

80

Intake air heater

F2

Green

30

Engine stop

F3

Blue

60

Engine start

F4

White

80

Alternator

Relays POSITION

DESCRIPTION

1

Timer relay

2

Arctic preheater timer relay

3

Preheater relay

4

Solenoid stop relay

5

Engine start enabling relay

SIDE INSTRUMENT PANEL RELAYS POSITION

DESCRIPTION

g

3rd speed fan relay

h

Air conditioner relay

i

Return to dig relay

j

Automatic power relay

1)

Fan load relay

The relays g h i j and 1) are positioned inside the right dashboard; to reach them, lift the dashboard panel 1! after removing the relevant fastening screws 1@.

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OPERATION FUSES AND RELAYS - A90009 AND UP

When changing a fuse, make sure that the ignition switch is in the OFF 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. If the engine does not turn when the ignition switch is turned to START, check the engine start fuse and change if necessary.

EQUIPMENT FUSES AND RELAYS The fuses and relays are grouped on a single base positioned inside the front dashboard and protected by a flap door b.

The following tables indicate the characteristics and the functions of the single fuses and relays.

Fuses POSITION

COLOR

AMPS

INVOLVED CIRCUIT

F1

A B C

Light blue Violet Violet

15 3 3

Low beam Rear right and front left parking light Rear left and front right parking light

F2

A B C

Red Light blue Red

10 15 10

--Cab dome light - Radio - Lighter - Revolving light Emergency power supply

F3

A B C

Brown Brown Brown

7.5 7.5 7.5

Stop lights - Seat sensor - Differential lock Instruments - Warning lights - Switch lights - Return to dig OPT Solenoid valve - Trans disengage relay power supply

F4

A B C

Brown Red Light Blue

7.5 10 15

Four wheel drive - Front wiper Direction selector High beam

F5

A B C

Red Light blue Light blue

10 15 15

Heater motor relay - Power econ unit - Seat electric unit Rear working light Front working light

F6

A B C

Light blue Brown Red

15 7.5 10

Rear horn - Rear wiper Dimmer switch - Front horn relay Direction indicators

F7

A B C

Brown Red Brown

7.5 10 7.5

--Front horn Engine stop solenoid

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OPERATION

Relays POSITION

DESCRIPTION

K1

Forward gear relay

K2

Reversing gear real - Reversing gear audible alarm

K3

Four wheel drive relay

K4

Start relay

K5

Low beam relay

K6

High beam relay

K7

Direction selector power supply relay

K8

Front horn relay

K9

Blinker relay

K10

4th gear signaling relay

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OPERATION ENGINE FUSES AND RELAYS The fuses and relays are grouped on a single base positioned inside the engine compartment and are protected by a cover b.

This unit can be reached by opening the engine hood, see ENGINE HOOD on page 2-71.

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OPERATION Fuses POSITION

COLOR

AMPS

F1

Blue

60

Key block power supply

F2

White

80

Engine stop

F3

Orange

40

Engine start circuit

F4

Orange

40

Heater/AC fan - High and low beam - Electric outlet

DESCRIPTION

Relays POSITION

DESCRIPTION

1

Engine stop enabling timer

2

Preheater timer

3

Glow plug preheater relay

4

Solenoid pull relay, engine stop

5

Safety relay, against repeated starts

6

Battery alarm warning light resistance

SIDE DASHBOARD - STANDARD Relays POSITION

DESCRIPTION

b

Differential locking - Stop lights

c

Seat safety relay

d

Automatic power relay

e

Return to dig relay

f

Fan 3rd speed relay with AC

g

Fan relay

These relays are positioned inside the right dashboard; to reach them, lift the dashboard cover h, after removing the relevant fastening screws i.

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OPERATION SIDE DASHBOARD - PPC SYSTEM Relays and Fuse The servo control unit b, power supply relay c and the fuse F3 are installed on the machine. They are positioned inside the right dashboard. To reach them it is necessary to lift the dashboard cover e, after removing the relevant fastening screws f.

POSITION

b c

DESCRIPTION Servo control unit Power supply relay

POSITION

COLOR

CAPACITY

DESCRIPTION

F3

Light blue

15 Amp

Servo control power supply

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OPERATION

ENGINE HOOD

Do not open the engine hood when the engine is running. Do not use the machine without engine hood and do not start the engine when the hood is open, unless this is expressly prescribed for certain maintenance operations. Before opening the hood, lower the equipment to the ground and apply the parking brake. Before carrying out any maintenance operation inside the engine compartment, park the machine on firm and flat ground, raise the loader boom and engage the safety lock. Noncompliance with these rules may result in serious accidents.

1. After releasing the lock, press the push button b, raise the hood c and open it completely.

2. To close the hood, lower it slowly and push it downwards until the lock snaps. Lock the hood.

OPERATOR’S COMFORT CANOPY The safety canopy b is a combined ROPS/FOPS; if it is subjected to an impact for any reason, or if the machine overturns, contact your distributor immediately to have the canopy replaced.

CAB

The cab is a combined ROPS/FOPS; if it is subjected to an impact for any reason, or if the machine overturns, contact your 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. Before starting the machine, make sure that the right door, emergency door, is not locked.

GENERAL The cab features a rear upper window that can be opened completely; once opened, this window must be secured to the upper part of the cab, parallel to the roof. The rear lower window, instead, is fixed. The side windows can be opened partially or completely, even if the doors are completely closed. These solutions are particularly useful during the summer, since they ensure constant air circulation and therefore reduced stress for the operator.

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OPERATION REAR WINDOW The rear window b can be opened only after releasing the couplings c, by pulling and lifting the window itself.

Once the window has been positioned, fit the couplings c in the upper safety couplings.

SIDE WINDOWS The side windows can be opened only after releasing the safety lock i. Proceed in the following order: 1. First press the button j to release the safety lock and then the locking lever d.

2. To open the side windows completely, it is necessary to rotate the windows completely and to engage the couplings e in the elastic blocks f provided on the door.

3. When closing the side windows, always engage the safety lock by pressing the button 1).

The side windows must always be locked or closed. When the side windows are closed, always engage the safety lock i. Periodically lubricate the elastic blocks f to facilitate the engagement of the couplings.

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OPERATION The side windows can be opened partially or completely. To open them partially, proceed as follows: 1. Release the lever d from the lower coupling pin e, following the direction indicated by the arrow, A.

2. Lift the lever d with a simple sliding movement and at the same time push the lever toward the outside of the cab.

After lifting the lever, push its end downwards in order to engage it in the upper coupling pin f, B.

If it is necessary to open the side windows completely, proceed as follows: 3. Release the lever d from the upper coupling pin f following the direction indicated by the arrow, C.

4. With the window open, lower the lever d until engaging it in the lower coupling pin e, D.

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OPERATION 5. Rotate the side windows towards the front of the machine, until engaging the coupling g in the rubber block h, E. 6. To close the side windows, repeat the operations described above in the reverse order, remembering that the lever d must always be engaged in the lower coupling pin e, A. Remark When the side windows are partially or completely closed, they must always be engaged in the lower e or upper f coupling pin by means of the lever d. When the side windows are rotated towards the front of the machine in order to open them completely, make sure that they are perfectly locked in the relevant rubber blocks h. Periodically lubricate the rubber blocks with specific greases, in order to facilitate the coupling operation.

ENTRY DOORS The cab entry doors can be opened even partially; the partial opening is obtained by fitting the locking devices i in the handle support recesses j.

The doors must always be secured with the locking devices i or closed.

OPERATOR ENVIRONMENT The ventilation and heating of the cab serve to reduce the operator’s stress either in the summer or in the winter. These functions also serve to eliminate the condensate from the front window, thus ensuring visibility during both work and travel.

Ventilation and air change are achieved by means of a 3 speed fan assembled to the outside of the machine, under the cab. The intake air is protected by a filter positioned on the right side of the cab, while the distribution is obtained through a series of adjustable openings with variable delivery b, either for the side flows or for the flows that serve to defrost and defog the front window.

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OPERATION A radiator having the function to heat the air conveyed into the cab is installed beside the fan. This is used in the cold season and receives the hot water necessary for the heat exchange directly from the engine cooling circuit. The water supply flow is divided or excluded by means of a tap operated by a handwheel c positioned on the side dashboard. The flow intensity is adjusted by rotating the handwheel clockwise.

The ventilation and heating system can also provide for the recirculation of the air inside the cab, which is obtained by opening the outlet d. This function ensures quicker heating and is very useful when working in areas where air pollution is considerable, tunnels, dusty places, small or badly ventilated rooms, etc.

If the operator deems it necessary, the machine can be equipped with air conditioning system, in addition to the ventilation and heating system. This is particularly useful in the hot season, when the temperatures are rather high.

Do not use the air recirculation function for long periods in rainy or cold days, since this would increase the fogging of the inside of the windows.

AIR CONDITIONER

The coolant used in the air conditioning system is very dangerous. If it is sprayed into the eyes or in case of contact with the skin, wash with plenty of water and consult a doctor without delay. Furthermore, to avoid any explosion, do not generate sparks and use open flames near the air conditioner. The refrigerant contained in the air conditioning system is considered special waste and must be recovered and disposed of according to the EPA and/or any anti pollution regulations in force. For specific maintenance operations to be performed on the air conditioning system, contact your distributor. Noncompliance with these instructions may cause serious damage and even death

Before operating the air conditioner, interrupt the circulation of hot water in the engine by rotating the valve h positioned in the engine compartment clockwise.

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OPERATION The ventilation and cooling of the cab have the specific purpose of reducing the stress to which the operator is subjected, when the outside temperature is very high. The air conditioning system can be operated by proceeding as follows: 1. Press the switch b positioned on the right dashboard.

2. Turn the knob c counterclockwise to adjust the temperature.

3. Turn the knob d to select the desired air flow among the 3 options available: pos.: 1, 2 or 3.

4. Once one of the three air flow speeds has been selected, the green warning light on the switch b will come on to indicate that the air conditioning system is in operation.

Once started, the system is controlled by a thermostat that intervenes when the evaporator positioned under the seat reaches the maximum or minimum temperature allowed. The distribution of air inside the cab takes place through the same air vents used for the heating system, with the addition of the side air vents g.

The air conditioning system is also provided with a special duct for the recirculation of air inside the cab. To use the air recirculation function, turn the knob e clockwise. In this way the suction of air from the outside is interrupted, while there is a continuous air recirculation inside the cab.

The filter f positioned on the right dashboard has the function to filter the recirculating air, so that the air flow obtained is constantly clean.

Periodically clean the filters, with time intervals to be determined according to the environment in which the machine operates, min every 5 days to a max every 15 days. To clean the filters, see CAB AIR FILTERS on page 3-24.

The air recirculation function serves to obtain a quicker cooling of the cab and is very useful when working in extremely polluted areas, tunnels, very dusty places, small or closed places, etc.

To switch off the air conditioner, toggle the switch b to the off position. When the green warning light in the switch goes out, that confirms that the air conditioner is off.

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OPERATION Even in the periods in which the air conditioner is not used, operate the compressor at low speed for approximately 3 to 5 minutes at least once a month. This operation ensures the lubrication of all the moving parts of the compressor.

SAFETY SEAT BELT

Fasten the safety belt before starting the engine. The safety belt must be changed when it is frayed, damaged or worn and in any case every 4 years.

The safety belt B consists of two coupling points and a length adjustor C. It must be tight and hold the operator’s hips, while leaving the upper part of the body free.

DRIVER’S SEAT The seat is designed for maximum operator comfort which helps reduce operator fatigue. There are six seat adjustments: •

Fore and aft adjustment ...............................................

•

Back angle adjustment.................................................

•

Adjustment of seat suspension ....................................

•

Seat cushion height......................................................

•

Armrest adjustment ......................................................

•

Rotation for backhoe operation ....................................

b c d e f g

The operator can choose the most comfortable operating position by using the listed features. For fore to aft adjustment, lever b can be used to position the seat in a forward to backwards position. The back adjustment c is for positioning the upright inclination for the operator’s back angle. The softness or dampening of the ride and vibrations can be controlled by adjusting knob d to the desired setting. To increase firmness, turn the knob clockwise, to decrease firmness turn the knob counterclockwise. The height of the seat can be adjusted with lever e either up or down.

To adjust the armrest angle, use the roll knobs f to change the inclination of the arm rest angle. When operating the backhoe, use lever g to rotate the seat from the loader position to the backhoe position.

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OPERATION SAFETY EQUIPMENT AND STORAGE AREAS FIRE EXTINGUISHER The machine owner must provide a fire extinguisher for the machine. Storage area b is provided in the cab to hold the fire extinguisher.

If your machine is equipped with a fire extinguisher, learn how to use it. Before starting any work operations always check the fire extinguisher to be sure it is fully charged and in working condition.

FIRST AID KIT The machine owner must provide a first aid kit for the machine. A storage area b is provided in the cab to hold the first aid kit.

Check the first aid kit frequently to be sure it is in good condition and the medical supplies are not damaged or missing.

DOCUMENT STORAGE A pouch on the back of the seat is provided for the storage of any service documents.

TOOL CASE An additional tool case, located on the rear outer part of the cab is for storing extra tools, if needed. When using the tool case b, firmly close the cover c to prevent tools from falling out.

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OPERATION

OPERATING THE MACHINE CHECKS BEFORE STARTING THE ENGINE VISUAL CHECKS

Dirt, oil and fuel in the engine compartment near its hot parts may damage the machine and even cause fires. Check frequently and eliminate any leakage; if leakages occur repeatedly, contact your distributor.

Before starting the engine, check around and under the machine to verify: 1. If there are loose screws or nuts. If there are oil, fuel or coolant leakages. The wear of the work equipment.

2. The fastening of the electrical connections.

3. The fastening of the engine exhaust pipe and manifold.

4. The conditions of the rims and the wear of the tIres.

5. If the safety and warning plates are sufficiently clean.

6. If the ladders and the handles for the access to the operator’s seat are clean.

Any leak or abnormality must immediately be repaired/eliminated and any trace of oil or grease must be removed. Further visual checks concern: 7. The condition of the safety belt. The efficiency of the instruments and of the dashboard.

8. The condition of the cab windows and the efficiency of the lights, working lights and direction indicators.

DAILY CHECKS

Do not smoke during fuel and oil filling and do not use open flames or non approved lighting to check the fuel and oil level, in order to not cause fires. If fuel, oil, or lubricant is spilled while filling the tanks, clean the dirty areas immediately.

Before starting any operation, check the engine coolant, engine oil and hydraulic circuit oil levels and lubricate the pivot points, see EVERY 10 HOURS OF OPERATION on page 3-20. At the end of work shift, provide for refuelling, in order to avoid the formation of condensate, always checking the fuel level on the indicator provided on the dashboard.

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OPERATION

Avoid filling the tank completely, in order to leave room for the fuel or oil to expand. After filling the tank, replace the filler cap, making sure that the bleed hole is completely open.

Check the engine oil level with the machine in a horizontal position and the hydraulic circuit oil level with the front bucket resting on the ground and the backhoe in transport position.

OPERATIONAL CHECKS

All the checks must be carried out by the operator while seated, with fastened safety belt. When the machine is stopped after use or maintenance, some safety locks may not be engaged; when the operator gets into the cab, he must make sure that all the mechanical safety locks are engaged and that the equipment cannot move suddenly and create dangerous situations.

The checks concern: 1. The coupling of the safety locks for the front bucket and the backhoe control levers.

2. The hand accelerator idle position.

3. The directional lever neutral position.

4. The gearshift neutral position.

5. The application of the parking brake.

The following check is carried out by turning the ignition key to position I to apply voltage to the control panel and check the functionality of: the acoustic alarm, the fuel level indicator and the engine oil pressure, generator, preheating, parking brake warning lights.

CHECKING THE FUEL SUPPLY Before starting the machine it is important to be sure there is enough fuel in the fuel tank. To check, turn the ignition key to the ON position and read the fuel gauge b. If fuel is low, add fuel. Be sure when filling the fuel tank you leave enough space in the tank for the fuel to expand. Never overfill the fuel tank. Do not smoke when refueling. Do not use fuel additives or mix gasoline with diesel fuel. Additives may damage the fuel pump and injector parts.

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OPERATION STARTING THE ENGINE

Before starting the engine be sure all personnel are clear of the work area or travel path. Be sure the gear shift lever is in neutral N. The engine will not start with the directional lever in forward or reverse. 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 maneuvers and noncompliance with the safety regulations and the rules of the road. Before starting the engine, make sure that there is no one within the operating radius of the machine and sound the horn. A safety device does not allow the machine to be started with gears engaged or travel direction selected. The machine is also equipped with an acoustic alarm that is activated when the operator, with the engine running, shifts the directional gear control lever from the neutral position with the seat rotated and not in the correct driving position.

TEMPERATE CLIMATES 1. Press the accelerator pedal to the floor and turn the ignition key to START position .

2. As soon as the engine starts, release the ignition key, which will automatically return to position I and reduce the engine speed to idle.

If the engine does not start within 15 seconds, release the key, which will automatically return to position I and wait for 15 seconds before trying again.

COLD WEATHER

Do not use any starting fluids or ether to assist in starting an an engine in cold weather. These products may cause an explosion, damaging the engine or causing injury.

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OPERATION 1. Turn the key to the preheat position for a maximum of 15 seconds in the coldest weather. The preheat time is determined according to the outside temperature and the ratio is about 1 second for each degree below 0°C.

2. Press the accelerator pedal to the floor and turn the ignition key to START position for a maximum of 15 seconds.

3. As soon as the engine starts, release the ignition key, which will automatically return to position I and reduce the engine speed to idle.

If the engine does not start on the first attempt, repeat operations 1 and 2 after waiting for at least 30 seconds, in order not to overload the battery.

WARMING THE ENGINE 1. After starting the engine, let it warm up before starting work.

The ideal warm up of the engine is achieved with a constant speed of 1200 rpm, obtained with the hand accelerator, see HAND THROTTLE on page 2-32.

Do not accelerate completely or abruptly until the coolant temperature has reached at least 60°C, which can be checked by means of the gauge provided on the dashboard.

2. To reduce the time necessary to warm up the engine, accelerate now and then, up to maximum 1800 rpm. During the warming up of the engine, check the color of the exhaust gases and verify if abnormal noises or vibrations can be noticed; any abnormality must be verified and its cause must be eliminated.

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OPERATION HEATING THE HYDRAULIC OIL When warming up the engine, especially in the cold season, it is advisable to also heat the hydraulic system oil. For this reason, when the coolant temperature has reached approximately 60°C, proceed as follows: 1. Remove the lock from the front bucket control lever, see SAFETY LOCK USAGE on page 1-38.

2. Raise and rotate the front bucket slowly and completely for several cycles.

3. Lower the bucket to the ground and lock the control lever.

4. Rotate the seat, remove the backhoe control levers locks, see SAFETY LOCK USAGE on page 1-38.

5. Extend and retract the arm and the bucket completely for several cycles.

6. Relock the levers and rotate the seat to the driving position.

MOVING THE MACHINE

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. Before moving the machine, sound the horn to make sure that there is no one within the operating radius of the machine and that there are no obstacles in the surrounding area. Be extremely careful when engaging reverse and make sure that there are no persons, working means or obstacles in the way. The brake pedals must be connected with the appropriate pin.

After warming up the machine, apply the service brake and then release the parking brake. To release the parking brake, squeeze the safety lever until the parking brake lever can be forced downward. The gear shift lever remains locked in the neutral position until the parking brake is released.

Before moving the machine, check the instruments, warm up the engine and the hydraulic oil, make sure that the stabilizers have been raised and that both the front bucket and the backhoe are in transport position. The control levers must be in the neutral position N. At this point, release the parking brake.

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OPERATION Select: 1. The desidered steering mode.

2. The gear, by pressing the UP/DOWN buttons and checking the engaged gear on the display.

3. The travel direction, by shifting the control lever forward F or backward R within 3 seconds after engaging the gears.

4. Gradually accelerate with the accelerator pedal.

Remark The travel direction must be selected with the engine at low rpm, in order to avoid abrupt accelerations. For the operation of the gear shift lever and all its functions, see MACHINE CONTROLS on page 2-6.. The gear shift is completely synchronized, therefore no deceleration is necessary to change gears when the machine is going to keep travelling in the same direction. If it is necessary to shift down, first reduce the engine rpm and then shift down. For the operation of the steering unit, see STEERING CONTROL PUSH BUTTON UNIT on page 2-16..

ENGAGING THE FOUR WHEEL DRIVE

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 1st and 2nd gear; when the other gears are engaged, it is not possible to connect the four wheel drive.

When travelling on roads or removing the machine, disengage the four wheel drive.

The four wheel drive can be engaged and disengaged by means of the push button b positioned on the gearshift. It is normally used when the machine must move on muddy, icy, gravelly ground, on slopes and in any situation in which it is difficult to move the machine. The four wheel drive must be used even when the machine is provided with optional equipment to be employed as snow plow.

Remark The four wheel drive is automatically connected when the machine brakes with 3rd or 4th forward gear engaged.

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OPERATION WORKING ON SLOPES

Before starting to work on slopes, always check the functionality of the brakes and of the parking brake. Always engage the four wheel drive. Avoid engaging the high gears. Do not move downhill with the gears in neutral, but always keep low gears engaged. Noncompliance with these rules may cause you to lose control of the machine and possibly cause the machine to overturn. Do not risk serious injury or death.

Avoid using the declutch push button.

When working on slopes the following precautions should be taken to avoid risks for the operator and anyone in the vicinity; the checks and operations to be carried out are the following: 1. Always check the work area for snow, landslides, gravel, loose ground and anything that may suddenly modify the work conditions and the stability of the machine.

2. When it is necessary to travel downhill, the front bucket must always be directed downward, in transport position.

3. When loading or traveling uphill, the front bucket must always be directed upward.

4. When moving the machine during work, always lower the front bucket.

5. Carry out any lateral movement on a flat surface at the beginning or at the end of the slope. If this is not possible, move obliquely, keeping the machine axis as parallel to the slope direction as possible. Do not move too obliquely or, even worse, with the machine axis rotated 90° with respect to the slope direction.

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OPERATION MAXIMUM IMMERSION DEPTH

If it is necessary to work with the machine immersed in water or 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 exceed 50 cm and in any case that the engine cooling fan does not touch the water, since it may get damaged or even break.

When working in water or on muddy ground, lubricate the pivot points more frequently than usual. After work, remove any dirt or mud and lubricate the pivot points.

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OPERATION

PARKING THE MACHINE PARKING ON LEVEL GROUND

Park the machine on firm and flat ground, in a sufficiently wide space, so that the checks, daily lubrication and refueling can be carried out without problems. Lower the front bucket to the ground and set the backhoe in the transport position or with the bucket resting on the ground. Engage all safety locks and apply parking brake. Keep to all the safety rules, in order to avoid any movement of the machine when the operator is absent. When leaving the machine, remove the ignition key, use the ladders and handles, lock the cab.

1. Park the machine on firm, flat ground, in a sufficiently wide space.

2. Move both the gearshift and directional control levers to position N and apply the parking brake.

3. Rest the front bucket and the backhoe bucket on the ground; if this is not possible because the space is insufficient, the backhoe must be folded in the transport position and secured with the appropriate lock.

4. Insert the safety pin of the front bucket control lever and the safety lever of the backhoe levers.

5. Stop the engine, see STOPPING THE ENGINE on page 290.

6. Leave the driving position using the ladders and handles provided for this purpose.

7. Refuel taking the necessary precautions.

8. Remove the ignition key and lock the cab.

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OPERATION

PARKING ON SLOPES

The movement of the machine when the operator is not on board may cause serious accidents or even death; to prevent this, carry out the operations described below. Park on slopes only when it is absolutely necessary. Park only with the front bucket directed downwards.

1. Park the machine with the bucket directed downwards and resting against an obstacle. If this is not possible due to the absence of natural obstacles, rotate the bucket in the dumping position and thrust the teeth into the ground.

2. Shift the directional control lever to the neutral position and apply the parking brake.

3. Operate the backhoe controls until the bucket teeth are in the digging position and thrust them into the ground.

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OPERATION 4. Insert the safety pin of the bucket control lever and the safety lever of the backhoe levers.

5. Stop the engine following the procedure see STOPPING THE ENGINE on page 2-90.

indicated,

6. Leave the driving position using the ladders and handles provided for this purpose.

7. Put wedges under the wheels.

8. Refuel taking the necessary precautions.

9. Remove the ignition key and lock the cab.

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OPERATION

STOPPING THE ENGINE

The sudden stop of the engine while it is running shortens its life. Do not stop it suddenly, except in case of emergency. It is likewise recommended not to stop the engine suddenly if it has been running for a long period and is still hot; in this case, let the engine idle at a min speed of 1200 rpm for about 5 minutes, in order to allow it to cool down gradually before stopping.

Before stopping the engine, proceed as follows: 1. Rest the front loader and backhoe equipment on the ground.

2. Shift the levers to the neutral position and connect the safety devices.

3. Shift the hand accelerator lever to the idle position.

4. Move the gear shift - directional gear lever to the neutral position and apply the parking brake.

Stop the engine by turning the ignition key to OFF position

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OPERATION

TRANSPORTING THE MACHINE LOADING AND UNLOADING

The loading and unloading of the machine on/off the means of transport must be carried out on a flat surface and at a safe distance from the edges of ditches or from the road side.

Block the means of transport by positioning wedges in front of and behind each wheel. Make sure that the ramps are sufficiently strong; if necessary, reinforce them with blocks, in order to prevent any dangerous bending. Make sure that the ramps have the same length, are firmly anchored to the motor vehicle, are parallel to each other and perpendicular to the loading board; the distance between the ramps must be suitable for the machine gauge. Position the ramps with a maximum inclination of 15°. Remove any trace of oil, grease or ice from the ramps and the loading board. Do not change direction when the machine is already on the ramps; if necessary, return to the ground and reposition the machine.

1. The machine must drive on the ramps with the front bucket b directed forward and raised from the ground.

2. Once the machine has been loaded, rest the front bucket on the floor, set the machine in neutral, apply the parking brake and insert the locking pin of the bucket control lever.

3. Lower the backhoe bucket c onto the vehicle and connect the safety lock lever of the backhoe control levers. Stop the engine and remove the ignition key.

4. Keep the machine in position also by putting wedges d in front of and behind each wheel.

5. Secure the machine with tie downs or chains e in the anchorage points, A and B. 6. Protect the end of the exhaust pipe f.

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OPERATION TRANSPORT

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

1. Check the overall dimensions; the height, width and weight of the means of transport, machine included. It must be compatible with the road and any tunnel, subway, bridge, electric or telephone line that may be found on the way.

2. Adhere to the regulations in force regarding signals, speed limits, road traffic, permits, etc.

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OPERATION

COLD SEASON PRECAUTIONS During the cold season or in areas where the temperature is particularly low, especially during the night, it is necessary to take some countermeasures meant to limit the damage resulting from low temperatures.

FUEL AND LUBRICANTS 1. Change the fuel to the winter fuel ASTM D975N.1 when the ambient temperature is below -10°C. 2. Change the engine oil with an oil with suitable viscosity. For the relevant specifications, see FUEL COOLANT AND LUBRICANTS on page 3-6.

COOLANT

Coolant containing antifreeze is flammable; do not smoke and do not use open flames during the checks and when preparing the mixture. Do not use methanol, ethanol or propanol based antifreezes.

1. Use only permanent, ethylene glycol based antifreeze, with corrosion inhibitors and antifoam products.

2. The antifreeze to water ratio must be 1:1 (50% antifreeze and 50% water).

3. Do not use plugging additives, either alone or added to the antifreeze, to eliminate leakages.

4. Do not mix antifreezes of different brands.

5. The use of permanent antifreeze requires only the check of the level and the periodical change of the fluid. It is not necessary to wash the cooling circuit.

6. The required standards for the permanent antifreeze are SAE-J1034 and FEDERAL STANDARD O-A-548D. In case of doubt regarding the compliance of the antifreeze used with the standards, contact the manufacturer and ask for precise information.

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2-93

OPERATION BATTERY

To avoid explosions due to the presence of gas, do not provoke sparks and do not use open flames near the battery. The battery electrolyte is dangerous. If it comes in contact with the eyes or the skin, immediately rinse with plenty of water and consult a doctor without delay. To prevent the fluid from freezing, add distilled water in the morning, before starting work.

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.

2. Measure the specific weight of the fluid and check the battery charge percentage, making reference to the following table: CHARGE

FLUID TEMPERATURE 20째C

0째C

-10째C

-20째C

100%

1.28

1.29

1.30

1.31

90%

1.26

1.27

1.28

1.29

80%

1.24

1.25

1.26

1.27

75%

1.23

1.24

1.25

1.26

OTHER PRECAUTIONS 1. Before using the machine in normal operating conditions, carry out some slow movements either forward or in reverse, and operate all the bucket and backhoe cylinders slowly more than once. These operations serve to warm up and fluidize the oil in the hydraulic circuit, the transmission, the axles and the brakes.

END OF WORK PRECAUTIONS 1. Remove mud and water from the machine body. Park the machine on firm ground; if the machine must be parked near banks or ditches, park it on wooden boards in order to distribute the weight of the machine on a larger surface.

2. Be careful of water drops forming on the hydraulic cylinder rods: these drops must be completely removed, since if they freeze the cylinder gaskets may be damaged. After removing the water drops, protect the rods with oil.

3. Drain the condensate that may have formed in the hydraulic tank and in the water separator, to prevent the water from freezing during the night.

4. Since the battery capacity may decrease considerably at low temperatures, after work, cover the battery or remove it and store it at a suitable temperature.

2-94

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OPERATION

WARM SEASON PRECAUTIONS 1. At the end of the cold season, change the lubricants, the coolant and the fuel.

The coolant must be changed only if it is not permanent. For the relevant specifications, see FUEL COOLANT AND LUBRICANTS on page 3-6.

2. Make sure that the cooling fan belt is in good conditions.

3. Make sure that the fins of the radiator and of the heat exchanger are clean.

4. Check the radiator cap gasket and spring; in case of doubt regarding tightness and setting, change the cap.

WB150AWS-2N

2-95

OPERATION

OPERATING THE LOADER

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. The brake pedals can be separated to make them independent and reduce the steering radiuses; adopt this solution only if it is absolutely necessary, at low speed and with lowered bucket. Always warn the persons present in the work site, even if they are authorized, by means of the horn. The basic illustrations shown are those necessary for the correct use and utilization of the machine; the operator must get to know the controls, the described operating method, the use of the bucket position indicator and learn how to organize work in a free area, using low gears while seated in the driving position.

BUCKET POSITION INDICATOR With this indicator, the operator always knows the position of the front bucket with respect to the ground; when the bucket is resting on the ground, this position is indicated by the return of the rod b to the guide tube level.

The machine is provided with an automatic RETURN TO DIG device, the horizontal position of the bucket with respect to the ground is determined by the sensor c positioned on the cylinder and is reached when the sensor does not detect the rod b any longer. In case of malfunction of the device, check and if necessary carry out the required adjustments.

To adjust the sensor, see LOADER RETURN TO THE DIG POSITION on page 3-30.

ORGANIZING THE WORK AREA If, after a first inspection of the area, it appears to be uneven, encumbered with large obstacles or characterized by considerable height differences, before starting work it is advisable to level the ground as much as possible, both for the loader and for the vehicles to be loaded.

This preliminary operation will make work quicker, ensure better results and at the same time reduce the operator’s stress and the straining of the machine components; furthermore, this will considerably reduce the time necessary to load the trucks destined for the transport of the material.

The area to be cleared of obstacles requires the use of a truck positioned as indicated in the figure; for any other arrangement the movements of the loader must be reduced as much as possible.

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WB150AWS-2N

OPERATION LOADING HEAPED AND LEVEL MATERIAL 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.

3. Reverse the motion of the machine and dump the bucket into the truck. After unloading the material into the truck, use the return to dig device of the loader hydraulic system to accelerate the operations. Once the device has been connected, it lowers the arm completely and at the same time brings the bucket in perpendicular position with respect to the ground. This is particularly useful for the operator, since in this way the machine is ready for the successive loading phase.

Start loading the truck from the cab side and, if the material is sufficiently mixed, dump from the maximum height in order to increase the compaction of the material and its distribution on the loading platform.

LOADING OPERATIONS ON SLOPES

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. Only change directions when moving very slowly, with the bucket as low as possible. Avoid any transverse position with respect to the slope direction. Sudden movements of the bucket and dangerous positions may cause the machine to over turn and lead to serious accidents or even death.

WB150AWS-2N

2-97

OPERATION CHANGING THE GP BUCKET

When the coupling pins are removed or installed, chips may come off; always use gloves, goggles and a helmet. The change of the front equipment must be carried out by two persons, who must decide together the words and signals to use during operations. Do not use your fingers to center the holes, since they may be injured or even cut. The described procedures are valid also for the coupling of the mechanical pieces of the optional equipment.

1. Position the GP (general purpose) bucket on level ground.

2. Remove the check bolts b and the coupling pins c.

3. Change the bucket d, taking care to clean the pins and bushings and to grease the pins slightly before reinstalling them.

4. Put back the check bolts and tighten them. Lubricate the pins, see LUBRICATION DIAGRAMS on page 3-9.

USING THE BACKHOE

Use the machine only after rotating the seat 180° with respect to the correct driving position; for the specific procedure, see POSITION FOR DIGGING OPERATIONS on page 2-99.

The machine is equipped with an acoustic alarm that is activated if the operator, with the engine running, shifts the directional gear control lever from the neutral position with the seat rotated and not in the correct driving position. This is a danger signal, since it is absolutely forbidden to carry out any movement with the machine while working with the backhoe equipment or in any case with the seat rotated 180° with respect to the regular driving position. Remember the operator must carry out any movement of the machine while seated in the correct driving position, with locked seat and fastened safety belt. Always fasten the safety belt before starting any maneuver. Always lower the stabilizers before starting any digging operation. Before starting work, alert the persons in the vicinity by means of the acoustic signal integrated in the side dashboard or in the left backhoe control lever, if the machine is equipped with backhoe servo controls.

2-98

WB150AWS-2N

OPERATION BUCKET POSITIONS

When starting the bucket connection pins into the couplings of the arm and of the thrusting arm, be careful of the metal chips that may come off and cause serious injuries. Always wear safety goggles, thick gloves and helmet. Do not use your fingers to center the holes; in case of abrupt or uncontrolled movements they may be cut.

The bucket can have two positions: Pos. 1 Suitable for normal digging operations, ensures more power to the bucket.

Pos. 2 Suitable for operations on vertical walls, ensures the maximum swing and the maximum digging height on walls. In this position the tearing force is reduced.

POSITION FOR DIGGING OPERATIONS

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. Before raising the stabilizers, fold the equipment completely or rest it on the ground. Carry out all the possible movements and make sure that the control levers work properly. If visibility is not perfect or there are ducts or lines of any kind, work at reduced speed and ask the aid of another operator.

1. Fasten safety belt; Center the machine with respect to the digging line. Lower the front bucket b to the ground; force this position until lifting the front wheels c in order to transfer the weight onto the bucket.

2. Make sure that the machine is in neutral, apply the parking brake, and lock the front bucket control lever. Rotate seat 180° and unlock the backhoe control lever.

3. Remove the boom antirotation pin, place it in the opposite hole, and release the boom from the safety lock.

4. Accelerate with hand accelerator up to 1500 to1600 rpm and lower the outriggers d; this maneuver stabilizes the machine and avoids overloads on the rear tires. Start work.

WB150AWS-2N

2-99

OPERATION

DIGGING METHOD

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.

1. At the beginning of work, keep the bucket at the correct penetration angle.

2. Once the desired digging depth has been reached, position the bucket with its back parallel to bottom of the excavation and then start filling.

3. During the collection phase, make the bucket, the boom and the arm move simultaneously; combined movements facilitate the filling of the bucket and therefore increase productivity.

4. The removal depth must be correct and suitable for the type of ground; excessive depth may lock the movements, overload the engine and the pump and slow down the digging operations.

5. To dump on heaps, dump the bucket as soon as it gets near the dumping area; the inertia resulting from the movement will ensure the compaction of the material with no need to use the bucket for this purpose, which avoids impacts and vibrations that facilitate the wear of pins and bushings.

2-100

WB150AWS-2N

OPERATION

CORRECT The bucket works with its flat surface parallel to the ground.

INCORRECT The bucket is thrust down slowing the digging work.

INCORRECT

CORRECT DIGGING METHOD

The bucket is pushed up and therefore is not filled completely.

(Sequence 1 - 2 - 3)

CHANGING THE BACKHOE BUCKET

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. Do not use your fingers to center the holes, since they may be injured or even cut. The described procedures are valid also for the coupling of the mechanical constraints of the optional equipment.

WB150AWS-2N

2-101

OPERATION 1. Position the bucket on level ground, directing it so that the flat part of the bucket back rests on the ground. First, remove the tie rod pin b and then the arm connection pin c.

2. Change the bucket, taking care to clean the pins and bushings perfectly and to grease the pins slightly before reinstalling them. Install the arm coupling first.

3. Put back the safety stops d of the pins. Lubricate the pins by means of the special grease nipple, see LUBRICATION DIAGRAMS on page 3-9.

2-102

WB150AWS-2N

OPERATION

OFF SEASON BEFORE OFF SEASON

When draining the fuel, do not smoke or bring open flames near the machine. Place a container under the machine to gather the fuel and prevent it from spreading on the ground.

If some fuel is spilt, clean the dirty surface immediately. To protect the cylinder rods when the machine is not used, position the work equipment as shown in the figure. This serves to prevent the cylinder rods from rusting.

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 to prevent oxidation.

2. Drain and replace all the hydraulic circuit fluid and the lubricants (axles, reduction gears, converter and engine), adhering to the rules stated in the section regarding maintenance.

3. Change all the filtering elements, air cleaner, engine oil filter, hydrulic circuit filters, diesel fuel filter.

4. To avoid the deformation of the tire sidewalls, insert supports under the axles, in such a way as to relieve the weight of the machine.

5. Change the coolant, permanent coolant.

6. Drain the normal fuel and fill the tank with at least 10 l of special washing and protecting fuel.

WB150AWS-2N

2-103

OPERATION 7. Let the engine run for about 10 minutes, in such a way as to eliminate the residual normal fuel from the filters, the injection pump and the entire fuel supply system. This operation avoids the locking of the injection pump and the injectors. Stop the engine and refuel with normal diesel oil.

8. Remove the battery, check the electrolyte level and make sure that the battery charge is sufficient. Store the battery in a room with suitable temperature and periodically recharge it.

9. Grease the hydraulic cylinder rods and the equipment joints.

10. Seal the end of the exhaust pipe and the fuel tank cap.

11. Move the machine controls to the neutral position and engage the mechanical safety locks of the equipment controls.

12. Attach a warning notice on the steering wheel to indicate the condition of the machine.

13. Lock the cab doors, the fuel tank cap and the engine hood.

DURING OFF SEASON

If it is necessary to carry out a rust prevention treatment while the machine is kept indoors, open doors and windows to increase ventilation and avoid poisoning by gas.

Start the engine and move the machine for a short distance once a month, so that a new oil film covers all the moving parts and the surfaces of the components. Provide also for charging the battery.

AFTER THE PERIOD OF INACTIVITY

If the machine is stored without carrying out the monthly rust prevention treatment, have maintenance performed by your distributor.

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.

2-104

WB150AWS-2N

OPERATION ‘

2. Check all the fluid levels, engine oil, coolant, fuel, hydraulic circuit oil.

3. Make sure that the battery charge is sufficient and install the battery. Disconnect the engine stop solenoid.

4. Turn the ignition key directly to the start position and keep it there until the engine oil pressure warning light goes out.

5. This operation serves to start the circulation of the lubricating oil and to carry out a first lubrication cycle.

6. Reconnect the stop solenoid valve and start the engine.

Run the engine at accelerated speed (1200 rpm), for about 15 minutes.

7. While the engine is warming up, check the tire pressure and remove the protection grease from the hydraulic cylinder rods.

8. Before moving the machine, make sure that the instruments, lights, direction indicators and brake stoplight work properly.

9. Warm up the hydraulic cylinders, by slowly moving all the work equipment as soon as possible.

TROUBLESHOOTING HOW TO MOVE THE MACHINE

When moving the machine, use a wire rope suitable for the weight of the machine to be removed. Before recovering the machine, shift the gear lever to neutral and disengage the four wheel drive.

If the machine gets stuck in mud and cannot get out using only its power, or in case of breakdown, use a wire rope to recover it.

IF THE FUEL HAS BEEN COMPLETLY DEPLETED Before starting the engine, when the fuel has run out and therefore air has entered the fuel supply circuit, it is necessary to bleed the fuel supply circuit. For the necessary operations, see EVERY 500 HOURS OF OPERATION on page 3-22.

WB150AWS-2N

2-105

OPERATION BATTERY IS DISCHARGED

When checking or carrying out any operation on the battery, stop the engine and make sure that the ignition switch is in the OFF position. The battery produces hydrogen, which may explode. Do not use open flames and do not smoke near the battery, and avoid producing sparks. The battery electrolyte is made of diluted sulphuric acid that may corrode the clothes and even the skin; in case of contact with this fluid, immediately rinse the involved part with plenty of water. If the acid gets into the eyes, immediately rinse with plenty of water and consult a doctor without delay. When working on the battery, always wear goggles and gloves. When removing the battery, first disconnect the ground cable -; when installing the battery, first connect the positive cable +. If a tool comes into contact with the positive terminal and the machine structure at the same time, this may generate sparks with consequent risk of explosion. Carefully tighten the connection terminals, since false contacts may generate sparks with consequent risk of explosion. 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 -. When starting the engine with booster cables, always wear safety goggles. Take care to avoid any contact between the machine to be started and the machine used as a starting aid, to avoid sparks and therefore the explosion of the hydrogen produced by the batteries. The explosion of the battery causes serious damage and injuries. Take care not to invert the cables and connect the ground cable - last, as far from the battery as possible.

Remove the cables with great care; prevent the cables disconnected from the battery from touching other parts of the machine, to avoid the explosion of the hydrogen. The cables and pliers must be suitable for the current load that must be transferred. The battery to be used for starting must have greater capacity or at least the same capacity as the battery of the machine to be started. Make sure the cables and pliers are neither corroded, nor damaged. Make sure that the pliers hold the terminals firmly.

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OPERATION 1. Make sure that the ignition key is in OFF position.

2. Connect the positive poles + of the two batteries with each other A. 3. Connect the cable of the negative terminal - of the charged battery to the ground block of the machine to be started B. 4. Start the engine of the machine that supplies current and increase its speed.

5. Start the engine of the machine that is not running, see STARTING THE ENGINE on page 2-81.

When the engine has started, remove the cables in the reverse order of the way they were connected.

6. Disconnect the negative cable - from the ground connection of the engine that has been started and then from the battery B. 7. Disconnect the positive cable + first from the battery used for the starting and then from the exhausted battery A.

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2-107

OPERATION OTHER TROUBLES ★ Always contact your distributor when you have to carry out any of these operations. ✩

If the problem or its cause are not indicated below, contact your distributor for the necessary repair.

ELECTRICAL CIRCUIT TROUBLE

CAUSE

REMEDY ★ Check and repair any loose termi-

Lights do not work satisfactorily even with engine running at high speed

• Faulty cables

Lights come on intermittently with engine running

• Faulty fan belt tension

Alternator charge warning light does not go out with engine running and increasing speed

• Faulty alternator • Faulty cables

★ Change ★ Check and repair

Alternator emits an abnormal noise

• Faulty alternator

★ Change

Starter does not turn with key in START position

• Faulty cables • Battery charge insufficient • Faulty engine start fuse

★ Check and repair

Starter pinion engages and then disengages

• Battery charge insufficient

★ Charge battery

Starter makes engine run slowly

• Battery charge insufficient • Faulty starter

★ Charge battery

Starter disengages before engine has started

• Faulty cables • Battery charge insufficient

★ Check and repair

Engine oil pressure warning light does not come on when engine is stopped, ignition key in I position

• Faulty bulb • Faulty pressure sensor

★ Change ★ Change

Alternator charge warning light does not come on when engine is stopped, ignition key in I position

• Faulty bulb • Faulty cables

★ Change ★ Check and repair

nal and connection or replace the cable ✩ Adjust fan tension, see EVERY 250 HOURS.

✩ Charge battery ✩ Change

✩ Change ✩ Charge battery

HYDRAULIC SYSTEM TROUBLE

Pump emits an abnormal noise

Equipment control levers do not return automatically to neutral position Equipment moves only at low speed

2-108

CAUSE • No oil in the tank • Faulty pump • Hydraulic oil unsuitable for the temperature • Broken return spring or seized element

REMEDY ★ Fill the tank ✩ Repair or change

★ Change ★ Change spring or distributor element

• Faulty pump • Max. pressure valves out of range or not closed due to impurities • Dirty drain filter

★ Repair or change ★ Calibrate or change ✩ Change

WB150AWS-2N

OPERATION BRAKING SYSTEM TROUBLE

CAUSE

REMEDY

Braking not regular for both wheels

• Brake discs worn • No oil in brake pump • Air in braking circuit

★ Change ★ Fill and bleed circuit ★ Bleed circuit

Braking not regular on one side only

• Air in braking circuit • Brake disc worn

★ Bleed circuit ★ Change

CONVERTER TROUBLE

CAUSE

REMEDY

• Oil level low • Clutch pressure adjusting valve locked open.

• Faulty delivery pump • Clutch shaft or piston rings worn • Leakages due to clutch piston pump locked open

✩ Fill

Pump delivery insufficient

• Oil level low • Suction filter clogged • Faulty pump

✩ Fill ✩ Clean filter ★ Change

★ Remove, D & A the unit ★ Change

Overheating

• • • • •

Noisy converter

• Faulty pump • Damaged bearings

★ Change ★ Remove and change

• Low engine rpm causes stalling • Defect as if due to overheating

★ Check and adjust engine governor

Low pressure in the clutch

Lack of power

WB150AWS-2N

Damaged rings Faulty pump Oil level low Dirty heat exchanger Damaged heat exchanger

★ Clean element and seat ★ Change ★ Change rings ★ Clean valve carefully

✩ Fill ✩ Clean ✩ Change

✩ See remedies in case of overheating

2-109

OPERATION ENGINE TROUBLE Oil pressure warning light remains on even with engine at high speed

Steam comes out of radiator breather pipe

CAUSE

REMEDY

• Oil level in oil pan too low • Oil filter clogged • Oil unsuitable for the season

✩ Fill ✩ Change filter ✩ Change

• Fluid level low, fluid leakage • Fan belt slackened • Mud or limestone accumulated in cooling system

✩ Fill, repair ✩ Adjust belt tension

• Radiator fins damaged or closed • Faulty thermostat • Radiator cap loose or broken working at considerable altitude

✩ Change fluid and clean cooling system ✩ Repair or clean ★ Change ✩ Tighten cap or change unit

Temperature indicator always on the right end of the scale

• Faulty temperature indicator

★ Change

Temperature indicator pointer always on the left end of the scale

• Faulty thermostat • Faulty indicator

★ Change ★ Change

Engine does not start with starter running

• No fuel • Air in fuel system • Compression defect, valves with wrong clearance

✩ Refuel ✩ Bleed system

Exhaust gases white or light blue

• Too much oil in oil pan • Unsuitable fuel

✩ Correct oil level ✩ Change with suitable fuel

Exhaust gases occasionally tend to be black

• Air cleaner clogged • Faulty injectors • Faulty compression

★ Change ★ Adjust valve clearance

Combustion noise occasionally resembles a blow

• Faulty injectors

★ Change

• • • •

✩ Change fuel compliant with standards ✩ See defects of temperature indicator ★ Change ★ Adjust valve clearance

Abnormal noises, during combustion or in mechanical parts

2-110

Fuel with low cetane rating Overheating Exhaust silencer inside damaged Excessive valve clearance

★ Adjust valve clearance

✩ Clean or change

WB150AWS-2N

3MAINTENANCE

WB150AWS-2N

3-1

MAINTENANCE

GUIDE TO MAINTENANCE ★ Before opening the engine hood, engage safety locks of both the loader and backhoe. If it is necessary to check the hydraulic oil level in the reservoir, arrange the machine in the transport position, see SAFETY LOCK USAGE on page 1-38. Only perform operations on firm and level ground, after applying the parking brake. ★ Use Komatsu 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. ★ Always keep the machine clean. This makes it easier to locate any part causing problems. Keep the grease fittings, the breathers and the areas near the openings for the fluid level checks clean and prevent any impurities from getting into/on them. ★ Draining hot oil or coolant immediately after stopping the engine is hazardous. Wait for the engine to cool down to at least 40 to 50°C before draining hot liquids. After changing the oil or the filters, check if metal particles are present. If you find large quantities of metal particles, contact your distributor. Check and change the oil in clean locations and prevent any impurities from getting into the tank/container. ★ Before carrying out any maintenance operation, hang the warning plates on the ignition switch, control levers, and cab doors, to prevent anyone from starting the engine by mistake. When performing maintenance operations, always take the precautions indicated on safety plates applied on the machine. ★ Instructions for are welding.

1. Turn ignition key to the OFF position.

2. Disconnect the battery, first, negative - pole and then positive + pole. Disconnect the alternator.

3. Do not apply more than 200V continuously.

4. Connect the ground cable within 1 mm from the point on which welding will take place.

5. Avoid placing gaskets and bearings between the welding area and ground cable. ★ Do not use flammable fluids to clean machine parts. Keep exposed flames and lit cigarettes away from these fluids. When o-rings and gaskets are removed, thoroughly clean sealing surfaces and replace all o-rings and gaskets with new ones. Fit the o-rings and gaskets correctly when reassembling. ★ Avoid keeping loose objects or tools in your pockets: they may fall out and drop into the machine, especially when you open covers and work on the machine while bending over it. When washing the machine, do not direct high pressure water jet onto the radiator and heat exchanger. When washing the machine, protect electric system connectors and avoid getting the ignition switch wet. ★ Before starting work in mud, in rain, on seashores, or river banks perform general lubrication. Wash the machine immediately after work to protect components from rust. Lubricate equipment joints more frequently than usual. When working at dusty work sites, proceed as follows: 1. Check the air cleaner for any clogging and clean it more frequently than usual. Clean the radiator and the heat exchanger frequently, to avoid any clogging of the fins.

2. Change the diesel oil filter more frequently than usual. Clean the electrical components, especially the starter and alternator, to avoid any accumulation of dust. ★ Never mix oils of different brands. Do not top off with any oil different from oil used in the machine. If necessary, drain all the oil and fill tank with new different brand oil.

Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to the regulations in force. Combustible material of some components may become extremely dangerous if it burns. For this reason, avoid any contact of burnt material with your skin or eyes and do not inhale fumes.

3-2

WB150AWS-2N

MAINTENANCE

MAINTENANCE NOTES ★ Use only Komatsu genuine replacement parts. Do not mix different types of oil. Unless specified otherwise, oils and coolant used by Komatsu before delivery of the machine are as follows: ITEM

SPECIFICATIONS

•

Engine oil

SAE 10W-30 API classification CD

•

Hydraulic system oil

SAE 10W-30 API classification CD

•

Biodegradable hydraulic system oil. Only for machines in which the synthetic biodegradable oil type HEES (not of plant origin) is used.

PAKELO GEOLUBE HYDRAULIC EP-46

Hydraulic transmission oil

GM DEXRON® II D

•

SHELL.......................................................DONAX TD CALTEX ........... RPM TRACTOR HYDRAULIC FLUID •

Axle oil (front and rear)

CHEVRON ................ TRACTOR HYDRAULIC FLUID TEXACO ..................................... TEXTRAN TDH OIL MOBILE................................MOBILFLUID 422 or 424

•

Brake system oil

GM DEXRON® II D Ambient temperature above -10° C:

•

ASTM D975 no. 2 diesel oil

Fuel

Ambient temperature below -10° C: ASTM D975 no. 1 diesel oil

•

Permanent, ethylene glycol based antifreeze, with corrosion inhibitor for protection down to -36°C

Radiator coolant

GM DEXRON® II D is a registered trademark of General Motors Corporation

NOTES REGARDING THE ENGINE ENGINE OIL ★ Engine oil must be selected very carefully, since it lubricates the engine, which is the machine’s heart; the main maintenance operations required for engine oil are as follows: 1. Daily, check the oil level.

2. Check condition of the oil with periodic analysis.

3. Periodic oil changes.

COOLANT ★ Engine coolant serves to keep the engine at the correct temperature and therefore to ensure optimal operating conditions; check coolant level in the expansion tank daily and top off if necessary. The quantity of antifreeze to be added to the coolant depends on the minimum temperature in the place where the machine is working.

Use the following table: QUANTITY OF ANTIFREEZE TO BE ADDED TO THE WATER Min. ambient temperature

°C

-4

-6

-9

-12

-16

-20

-26

-32

-36

Quantity of antifreeze

l

1.4

2.1

2.8

3.5

4.2

4.9

5.6

6.3

7

Quantity of water

l

12.6

11.9

11.2

10.5

9.8

9.1

8.4

7.7

7

WB150AWS-2N

3-3

MAINTENANCE ★ Use water which has low mineral content. Do not use corrosion inhibitors containing soluble oil, since they damage the rubber couplings. In case of doubt, contact your distributor.

FUEL ★ Always use fuel suitable for the engine. Other fuels with different specifications may damage the engine or reduce its power. Always refuel at the end of the work day. ★ When refueling, make sure that there is no water on the fuel drum cover and take care not to draw condensation from the drum bottom. If fuel runs out, or if the fuel filter has been replaced, it is necessary to bleed the circuit.

NOTES REGARDING THE HYDRAULIC SYSTEM ★ Be extremely careful when performing maintenance on the hydraulic system, since the oil is very hot. The system is pressurized not only during work, but also at the end of work. ★ The maintenance operations required for the hydraulic system are the following: 1. Daily check the oil level in the tank.

2. Periodically change the oil filter.

3. Periodically change the oil and clean the suction filter. ★ Always bleed, purge, the system after changing the oil filter and the oil. When a component is removed from the circuit, check the gaskets and o-rings and change them if they are damaged. When a cylinder or a component of the hydraulic system is removed, after reassembly bleed the system by proceeding as follows: 1. Start the engine and let it idle.

2. Make all the cylinders perform 4 to 5 movements, stopping them at about 100 mm from the end of their stroke.

3. Slowly make all the cylinders reach the end of their stroke for 3 to 4 times.

NOTES REGARDING THE ELECTRICAL SYSTEM ★ If the cables are wet or their insulating material is damaged, the electrical system may short, and may result in machine malfunctions. The maintenance operations required for the electrical system are the following: 1. Check the alternator belt tension.

2. Check the alternator belt for damage or breakage.

3. Check the battery electrolyte level. ★ Do not remove or eliminate any electrical component installed on the machine and do not install any electrical component with characteristics different from those specified and approved by Komatsu. ★ Be careful to keep the electric system dry. When working on seashores or river or lake banks, protect the jack plugs from corrosion. Do not connect any optional device to the fuses, ignition switch, battery, relays, etc. For the installation of any optional equipment, contact your distributor. If any electric welding needs to be done, disconnect the battery and the alternator.

NOTES REGARDING LUBRICATION ★ Lubrication makes the operations carried out with the machine and work equipment smoother, while preventing wear and the noise that may be produced if the articulations are dry. ★ Lubrication is to be carried out with grease or oil. The maintenance operations required for the components that need lubricating are the following: 1. Check the fluid and lubricant levels. Change oil at recommended intervals.

2. Inject grease through the grease fittings.

3-4

WB150AWS-2N

MAINTENANCE ★ Use only the specified lubricants, according to the ambient temperature. Always clean the grease fittings before injecting grease and remove any excess grease after lubrication; this cleaning operation must be performed with extreme care on the revolving parts. Keep the lubricants at the correct levels; excessive or insufficient quantities are to be avoided.

PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING ★ The parts subject to wear such as filters, bucket teeth, etc. must be replaced according to the periodic maintenance intervals prescribed or when they reach their wear limit. The timely change of these parts ensures economical use of the machine. Use only Komatsu genuine parts, which alone can guarantee excellent quality and interchangeability.

ITEM

DESCRIPTION

QTY

CHANGE INTERVAL

Hydraulic oil filter

Cartridge

1

500 hours

Engine oil filter

Cartridge

1

500 hours

Fuel filter

Cartridge

1

500 hours

Converter oil filter

Cartridge

1

1000 hours

Air cleaner

Main cartridge Safety cartridge

1 1

When required

Front GP bucket

Edge Bolt Nut

1 8 8

When required

Front MP bucket

Tooth Bolt Nut

8 16 16

When required

2 2 2 3 3 3 4 4 4 5 5 5 6 6 6

When required

Backhoe buckets 12 in. wide ..............................

18 in. wide ..............................

24 in. wide ..............................

30 in. wide ..............................

36 in. wide ..............................

WB150AWS-2N

Tooth adapter Tooth point Tooth pin Tooth adapter Tooth point Tooth pin Tooth adapter Tooth point Tooth pin Tooth adapter Tooth point Tooth pin Tooth adapter Tooth point Tooth pin

3-5

MAINTENANCE

FUEL COOLANT AND LUBRICANTS SELECTION ACCORDING TO THE AMBIENT TEMPERATURE Reservoir

Kind of Fluid -30°C -20

Ambient Temperature -10

0

10

20

30

Capacity 40

50°C

Specified

Refill

7.9 l

7.9 l

150 l

92 l

150 l

92 l

10.5 l

10.5 l

1.3 l each

1.3 l each

9l

9l

1.3 l each

1.3 l each

24.5 l

21.5 l

0.8 l

0.8 l

130 l

-

14 l

-

SAE 5W-30 SAE 10W SAE 20W-20 Engine oil pan

SAE 30 SAE 40 Oil API CD

SAE 10W-30 SAE 15W-40 SAE 5W* SAE 10W

Hydraulic system

SAE 30 SAE 10W-30

Hydraulic system with biodegradable oil

HEES

See page 3-12

Front axle Final gear Rear axle

Oil API CD

See Note 1

Final gear Trans Brakes Fuel tank Engine coolant

ATF Diesel Fuel Coolant

GM DEXRON® II D ASTM D975 No. 1

ASTM D975 No. 2 See page 3-4

*OPTION FOR VERY COLD AREAS: If the temperature exceeds -10°C, contact your distributor for advise on the type of oil to be used.

3-6

WB150AWS-2N

MAINTENANCE GREASE LUBRICATION POINTS

CONSISTENCY

TYPE

Articulations, grease fittings

NLGI 2

(See note 2)

Note 1: For axle oil, use only the recommended oil as follows.

SHELL:.............................................................................. DONAX TD CALTEX: .................................. RPM TRACTOR HYDRAULIC FLUID CHEVRON: ....................................... TRACTOR HYDRAULIC FLUID TEXACO: ............................................................. TEXTRAN TDH OIL MOBIL: ......................................................... MOBILFLUID 422 or 424 NOTE 2: The recommended lubricating grease is No.2 multi purpose lithium grease with 3% molybdenum disulfide (Lithio EP + MoS2).

Remark When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.

Fuel Sulphur Content

Change Interval of Engine Oil

0.5 to 1.0%

1/2 of regular interval

Above 1.0%

1/4 of regular interval

★ When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE10W, SAE20W-20 and SAE10W-30, even though an atmospheric temperature goes up to 10°C more or less in the day time. ★ Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. ★ There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 10W-40), but be sure to add single grade oil that matches the temperature in the table. ★ Use Komatsu genuine oil which has been specifically formulated and approved for use in the engine, hydraulic work equipment, transmission, axles, and brakes.

Specified capacity: Total amount of oil including oil for components and oil in piping.

Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

ASTM: ................................ American Society of Testing and Material SAE: ................................................ Society of Automotive Engineers API: ....................................................... American Petroleum Institute NLGI:............................................ National Lubricant Grease Institute

WB150AWS-2N

3-7

MAINTENANCE

HEES SYNTHETIC BIODEGRADABLE LUBRICANTS Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin, therefore use of oils indicated in the following table is authorized and recommended: SUPPLIER KOMATSU

HEES OIL ---

AGIP

ARNICA S 46

ARAL

HEF 46 vitam

AVIA

SYNTOFLUID N 46

BP

BIOHYD SE-S 46

CONDAT

CONDAT D 46 K

ELF

HYDRELF BIO 46

ESSO

HYDRAULIKOIL HE 46

FINA

BIOYIDRAN TMP 46 SE 46

FUCHS

PLANTOHYD S 46

KENDALL

SYNTH NATURA 46 HV

KUWAIT PETROLEUM K8

HOLBEIN 46

MOBIL

EAL SYNDRAULIC

MOBIL (USA)

ENVIROSYN 46 H

PAKELO

GEOLUBE HYDRAULIC EP-46

PANOLIN

HLP SYNTH 46

SHELL

NATURELLE HFE-46

TAMOIL

GREEN HYDRO SAFETY 46

TEXACO

HYDRA 46

TOTAL

EQUIVIS BIO 46

VAVOLINE

UNISYN HLP 32/68

It Is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when the temperature increases insoluble compounds are generated, which are deposited on the filters and clog them (the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil). The synthetic biodegradable oil can be used only in the hydraulic system; it cannot be used for the endothermic motor, the transmissions, the braking system, etc. Before introducing the synthetic biodegradable oil in the hydraulic system, empty the system completely, disconnecting the cylinders and all the parts that may contain ordinary oil, and replace the drain filter with a new one. Start the engine and let it idle without using the work equipment, wait until the oil reaches a temperature of at least 40°C, then start moving the equipment, so that all the parts of the system are filled with oil. Stop the engine and check the oil level, see ENGINE OIL LEVEL on page 3-33.

Note: Use only recommended oil and grease, see FUEL COOLANT AND LUBRICANTS on page 3-6. ★ For lubrication procedures for single points, see MAINTENANCE SCHEDULE on page 3-20.

3-8

WB150AWS-2N

MAINTENANCE

LUBRICATION DIAGRAMS GENERAL

WB150AWS-2N

3-9

MAINTENANCE MULTIPURPOSE BUCKET AND PALLET FORKS ★ Points indicated are symmetrical and must be lubricated every 10 hours. The fork sliding bars and safety pins must be lubricated with grease only to protect them from oxidation. Fork joints A must be lubricated only if the forks are used.

3-10

WB150AWS-2N

MAINTENANCE TELESCOPIC ARM ★ Points indicated are symmetrical and must be lubricated every 10 hours.

WB150AWS-2N

3-11

MAINTENANCE OFFSET BOOM ★ Points indicated are symmetrical and must be lubricated every 10 hours.

3-12

WB150AWS-2N

MAINTENANCE

PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY To ensure safety at any moment while driving and using the machine, the operator must carry out all periodic maintenance operations prescribed. Furthermore, the operator must periodically replace the components indicated in the table on the following pages, which are especially related to safety and fire prevention rules.

These components are subject to wear and since it is particularly difficult to evaluate their conditions through simple periodic maintenance, after a certain period it is advisable to change them independently of their state, in order to keep them efficient over time. Repair or replace these components immediately in case of failures or abnormalities, even if the time interval prescribed for their change has not elapsed yet. If the hose clamps show signs of deterioration, like deformations or cracks, replace them at the same time as the hoses.

In addition to periodic replacement of the components listed on the following pages, the inspections described below are to be performed on the hydraulic hoses. In case of abnormalities, perform the necessary adjustments and replacements, or institute any other required measure.

TYPE OF CHECK

CHECK ITEM

Check before starting

Leakage from joints, grease fittings, hydraulic hoses, or fuel lines.

Periodic check (monthly check)

Leakage from joints, fittings, hydraulic hoses, or fuel lines. Damaged hydraulic or fuel lines, cracks, wear and tear.

Periodic check (annual check)

Leakage from joints, fittings, hydraulic hoses fuel lines.

Deteriorated, twisted, damaged hydraulic hoses fuel lines, cracks, wear and tear, or in contact with other parts of the machine.

WB150AWS-2N

3-13

MAINTENANCE CRITICAL PARTS FOR SAFETY FUEL SUPPLY SYSTEM - A90002 TO A90008 NO

COMPONENTS THAT REQUIRE REPLACING

QTY

b

Fuel line (Fuel tank - precleaner)

1

c d e f g h i

Fuel line (Precleaner - fuel pump)

1

Fuel line (Fuel pump - fuel filter)

1

Fuel line (Fuel filter - injection pump)

1

Fuel line (Fuel filter - fuel tank)

1

Fuel recovery line (Injection pump - fuel filter)

1

Fuel recovery line (Injector - fuel filter)

1

Fuel recovery line (Between the injectors)

3

j

Fuel recovery plug

1

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual section regarding the components connected with safety and components that must be periodically replaced. When replacing hoses, always change o-rings, gaskets, and like components.

3-14

WB150AWS-2N

MAINTENANCE FUEL SUPPLY SYSTEM - A90009 AND UP NO

b c d e f

COMPONENTS THAT REQUIRE REPLACING

QTY

Fuel line (Fuel tank - precleaner)

1

Fuel line (Precleaner - fuel pump)

1

Fuel line (Fuel pump - fuel filter)

1

Fuel line (Fuel filter - injection pump)

1

Fuel line (Fuel filter - fuel tank)

1

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual section regarding the components connected with safety and components that must be periodically replaced. When replacing hoses, always change o-rings, gaskets, and like components.

WB150AWS-2N

3-15

MAINTENANCE DELIVERY RETURN HYDRAULIC SYSTEM NO

b c d e f

COMPONENTS THAT REQUIRE REPLACING

QTY

Hydraulic hose (Hydraulic pump - tube)

1

Hydraulic hose (Tube - backhoe valve)

1

Hydraulic hose (Tube - loader valve)

1

Hydraulic hose (Hydraulic pump - backhoe valve)

1

Hydraulic hose (Loader valve to backhoe valve)

1

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual section regarding the components connected with safety and components that must be periodically replaced. When replacing hoses, always change o-rings, gaskets, and like components.

3-16

WB150AWS-2N

MAINTENANCE LOADER AND BACKHOE HYDRAULIC SYSTEM NO

g h i j 1) 1!

COMPONENTS THAT REQUIRE REPLACING

QTY

Hydraulic hose (Cylinders - Loader boom)

2

Hydraulic hose (Cylinders - Loader bucket)

2

Hydraulic hose (Cylinders - Multi-purpose bucket)

5

Hydraulic hose (Cylinders - Backhoe boom)

2

Hydraulic hose (Cylinders - Backhoe arm)

2

Hydraulic hose (Cylinders - Backhoe bucket)

4

WB150AWS-2N

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

3-17

MAINTENANCE

★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual section regarding the components connected with safety and components that must be periodically replaced. When replacing hoses, always change o-rings, gaskets and like components.

OPERATOR’S SAFETY No

Components Needing Replacement

Qty

Interval

b

Safety belt

1

Every 4 years

3-18

WB150AWS-2N

MAINTENANCE

TIGHTENING TORQUE STANDARD TORQUE FOR BOLTS AND NUTS Thread (mm)

8.8

10.9

N•m

N•m

Pitch (mm)

Wrench (mm)

6 8 10 12 14

1 1.25 1.5 1.75 2

10 13 17 19 22

9.5 ± 1 23 ± 2 45 ± 4.9 77 ± 8 122 ± 13

13.5 ± 1.5 32.2 ± 3.5 63 ± 6.5 108 ± 11 172 ± 18

16 18 20 22 24

2 2.5 2.5 2.5 3

24 27 30 32 36

191 ± 21 262 ± 28 372 ± 40 511 ± 57 644 ± 70

268 ± 29 366 ± 36 524 ± 57 719 ± 80 905 ± 98

27 30

3 3.5

41 46

945 ± 100 1287 ± 140

1329 ± 140 1810 ± 190

SPECIFIC TORQUES

This torque table is not valid for bolts or nuts that contain nylon parts or spring washers.

Item

Description

N•m

Cab

Front support bolts Rear support bolts

196 ± 9.8 196 ± 9.8

Wheel lug nuts

Front Rear

350 ± 9.8 500 ± 9.8

Front bucket

Teeth

143 ± 9.8

Engine and transmission

Front support bolt Rear support bolt

196 ± 9.8 196 ± 9.8

WB150AWS-2N

3-19

MAINTENANCE

MAINTENANCE SCHEDULE WHEN REQUIRED ITEM

DESCRIPTION

OPERATION

PAGE

b

Engine air cleaner ..........................................

Check, clean or change.................................

3-23

c d e f g h i

Cab air filters ..................................................

Check and clean............................................

3-24

Brake system..................................................

Bleed air ........................................................

3-25

Cooling circuit .................................................

Flush..............................................................

3-26

Water separator..............................................

Clean .............................................................

3-27

Front wheels...................................................

Adjust toe in...................................................

3-28

Parking brake .................................................

Check and adjust...........................................

3-28

Service brake .................................................

Check braking................................................

3-29

j 1)

Brake pedals ..................................................

Adjust stroke..................................................

3-30

Return to dig...................................................

Adjust.............................................................

3-30

WHEN DEMOLITION HAMMER IS USED ITEM

DESCRIPTION

OPERATION

PAGE

1!

1@

Hydraulic oil drain filter ...................................

Change cartridge ...........................................

3-31

Hydraulic oil ....................................................

Change ..........................................................

3-31

CHECKS BEFORE STARTING ITEM

DESCRIPTION

OPERATION

PAGE

1# 1$ 1% 1^ 1& 1*

Various checks................................................

Check.............................................................

3-32

Fuel tank .........................................................

Check, add fluid .............................................

3-32

Coolant ...........................................................

Check, add fluid .............................................

3-33

Engine oil pan .................................................

Check, add fluid .............................................

3-33

Hydraulic oil tank ............................................

Check, add fluid .............................................

3-34

Water separator ..............................................

Drain water ....................................................

3-34

EVERY 10 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

1(

Joints ..............................................................

Lubricate .......................................................

3-35

3-20

WB150AWS-2N

MAINTENANCE FIRST 50 HOURS OF OPERATION ★ Only for machines in which synthetic biodegradable oil, type HEES is used.

ITEM

DESCRIPTION

OPERATION

PAGE

2)

Hydraulic oil drain filter (HEES oil only)..........

Change ..........................................................

3-37

EVERY 50 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

2!

2@ 2# 2$

Radiator..........................................................

Check coolant level, (add coolant) ................

3-38

Brake system .................................................

Check oil level ...............................................

3-38

Drive shafts ....................................................

Lubricate (6 points)........................................

3-38

Front and rear axle joints and pivot joint ........

Lubricate (5 points)........................................

3-39

2% 2^

Front and rear wheels ....................................

Check tire pressure .......................................

3-40

Electrical system ............................................

Check ............................................................

3-40

FIRST 250 HOURS OF OPERATION .

ITEM

DESCRIPTION

OPERATION

PAGE

2& 2* 2( 3) 3!

3@

Front axle .......................................................

Change oil .....................................................

3-41

Rear axle ........................................................

Change oil .....................................................

3-41

Hydraulic transmission ...................................

Change oil .....................................................

3-41

Hydraulic transmission filter ...........................

Change ..........................................................

3-41

Engine valves .................................................

Check clearance, (adjust)..............................

3-41

Hydraulic oil drain filter ...................................

Change ..........................................................

3-41

EVERY 250 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

3# 3$ 3% 3^ 3& 3*

Fan belt...........................................................

Check conditions and tension, (adjust) .........

3-42

AC compressor belt ........................................

Check conditions and tension, (adjust) .........

3-42

Radiators ........................................................

Clean outside ................................................

3-44

AC condenser .................................................

Clean outside ................................................

3-44

Battery ............................................................

Check electrolyte level, (add fluid) ................

3-45

Front axle........................................................

Check levels, (add oil) ..................................

3-45

3( 4) 4!

Rear axle ........................................................

Check levels, (add oil) ..................................

3-46

Hydraulic transmission....................................

Check level, (add oil) ....................................

3-46

Front and rear wheels.....................................

Check lug nut tightness ................................

3-46

WB150AWS-2N

3-21

MAINTENANCE FIRST 500 HOURS OF OPERATION ★ Only for machines in which synthetic biodegradable oil, type HEES is used.

ITEM

DESCRIPTION

OPERATION

PAGE

4@

Hydraulic oil and suction filter .........................

Change oil and clean filter .............................

3-47

4#

Hydraulic oil tank ............................................

Drain condensation........................................

3-47

EVERY 500 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

4$ 4% 4^

Engine oil........................................................

Change ..........................................................

3-48

Engine oil filter................................................

Change ..........................................................

3-49

Hydraulic oil drain filter ...................................

Change ..........................................................

3-49

4& 4* 4(

Fuel filter.........................................................

Change ..........................................................

3-50

Fuel tank.........................................................

Drain condensation........................................

3-52

Hydraulic oil tank ............................................

Drain condensation........................................

3-52

EVERY 1000 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

5) 5!

5@ 5# 5$

Front axle .......................................................

Change oil .....................................................

3-53

Rear axle ........................................................

Change oil .....................................................

3-54

Hydraulic transmission ...................................

Change oil .....................................................

3-55

Hydraulic transmission filter ...........................

Change ..........................................................

3-55

Engine valves .................................................

Check clearance, adjust ................................

3-56

EVERY 2000 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

5% 5^ 5& 5* 5(

Hydraulic oil and suction filter .........................

Change oil and clean filter .............................

3-57

Coolant ...........................................................

Change ..........................................................

3-59

Brake system oil .............................................

Change ..........................................................

3-61

Alternator and starter ......................................

Check.............................................................

3-61

AC system coolant..........................................

Check level of refrigerant...............................

3-62

EVERY 4000 HOURS OF OPERATION ITEM

DESCRIPTION

OPERATION

PAGE

6) 6!

AC system filter...............................................

Change .........................................................

3-63

AC system compressor...................................

Check ............................................................

3-63

3-22

WB150AWS-2N

MAINTENANCE WHEN REQUIRED b AIR CLEANER CARTRIDGE

Remove the air cleaner only after stopping engine, and do not start engine after the air cleaner is removed. Always wear safety goggles during cleaning operations.

Remark The air filter system consists of a primary filter element with considerable capacity and of a secondary cartridge that ensures additional safety protection. The primary element can be cleaned with compressed air, while the cartridge must be replaced. The filter must be cleaned when the clogging warning light A positioned on the side dashboard comes on or flashes.

The air cleaner can be reached after raising the loader boom, engaging the mechanical safety lock and opening the engine hood.

To clean the primary element, proceed as follows: 1. Release the safety lock b, moving it toward the outside.

2. Rotate the cover c counterclockwise 12.5°. Lift the cover c and remove the filter element d.

3. Lightly tap the filter element d on the palm of your hand, in a manner to remove the dust, and blow compressed air on the inner surface. Keep the air jet at a distance of about 15 cm and prevent pressure from exceeding 4 to 5 kg/cm².

4. Carefully clean the inside of the filter case e, taking care to prevent foreign debris from getting into the suction duct.

5. Reinstall the filter element d, making sure that it is perfectly seated in its housing.

6. Reinstall the cover c, rotating it clockwise about 12.5°.

Make sure that the cover is perfectly locked and that the ejector f is positioned vertically on the lower part.

7. Once the unit has been reassembled, push the safety lock b towards the inside.

Remark If the warning light comes on after starting the engine, it is necessary to replace the primary filter element and safety cartridge. Replace the primary filter element after 6 cleaning operations or after one year. Every time the primary filter element is replaced, the safety cartridge must also be replaced.

WB150AWS-2N

3-23

MAINTENANCE To change the safety cartridge, after removing the primary element, then proceed as follows: 1. Remove the safety cartridge g and replace it with a new one.

2. Once the safety cartridge g has been installed inside the filter case e, make sure that it is perfectly seated in its housing.

3. Reassemble the unit as described above, making sure that all filter components are perfectly locked.

4. Push the safety lock b towards the inside.

c CAB AIR FILTERS

Always wear safety goggles during cleaning operations.

Air suction for ventilation of the cab is protected by a filter positioned on the right side of the cab. This filter blocks impurities contained in the air and must be cleaned whenever a decrease in air circulation is observed. The filter can be reached from the outside of the cab. To clean the filtering element, proceed as follows: 1. Remove the screws b, external protection c, and filter element d.

2. Tap the element lightly on the palm of your hand to remove dust. Blow compressed air on its surfaces, keeping the jet at a distance of about 5 cm and taking care to prevent air pressure from exceeding 4 to 5 kg/cm².

3. Carefully clean the filter casing, taking care to prevent any foreign debris from entering the suction duct, and then reassemble the unit.

With Air Conditioner If the machine is equipped with air conditioning and with an external filter d there is also an additional internal filter g for air recirculation. This filter removes the impurities present in the air and it must be cleaned whenever a decrease in the air circulation is observed. The filter can be reached from inside the cab. To clean the filter element, proceed as follows: 1. Remove the screws e, outer guard f, and filter element g.

3-24

WB150AWS-2N

MAINTENANCE 2. Tap the element lightly on the palm of your hand to remove dust and blow compressed air on its surfaces, keeping the jet at a distance of about 15 cm and taking care to prevent pressure from exceeding 4 to 5 kg/cm².

3. Carefully clean the filter casing, taking care to prevent any foreign debris from entering the suction duct, and then reassemble the unit.

d BRAKE SYSTEM

Oil spilled on the floor may cause it to become slippery; immediately clean any dirty area. Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

1. Make sure that oil in the brake system tank d is at the maximum level.

2. Depress each brake pedal and keep it depress while loosening the drain screw b for each brake, until the pedal reaches the end of its stroke. Keep pedal at the end of its stroke while tightening drain screw.

3. Release the brake pedal, wait for a few minutes and repeat the operations above until no air bubbles can be seen in the oil that flows out of drain screw b.

Remark When bleeding the system, attach a small hose to the bleeder screws b to collect the oil.

Bleeding must be carried out for both braking units, disconnect the tandem pedals from each other.

Frequently check the oil level in the brake system tank and top off whenever the oil is near the minimum level.

When adding oil, use only new oil of the prescribed type, see FUEL COOLANT AND LUBRICANTS on page 3-6.

WB150AWS-2N

3-25

MAINTENANCE e COOLING SYSTEM

Be extremely careful when performing this maintenance operation. Since the engine must be running, one operator must remain on the machine and another operator helping after they decide on words and signals to use. After work, when the machine is stopped, the coolant is very hot and under pressure and may cause serious burns. Let the engine cool down until it reaches 40 to 45°C before starting the flushing operations. Slowly loosen the radiator cap, to release residual pressure. Engage all of the work equipment safety locks.

Apply the parking brake and do not move the gear shift lever.

Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

Whenever changing from water to using antifreeze fluids, and vice versa, it is necessary to flush the system in order to eliminate oxide deposits and/or limestone deposits. Proceed as follows: 1. Remove the front guard b and hardware c. Open the engine hood.

2. With the fluid still warm, open the radiator drain e, loosen the drain valve f positioned on the filter head and loosen the radiator cap d.

3. Let all the fluid flow out. Tighten the valve f on the filter head at engine and close the radiator drain e.

4. Pour a high quality scale remover into the radiator, in doses recommended on the package, capacity of the cooling system; 14 l. Fill the radiator with water.

5. Start the engine and let it run at high rpm for about 15 minutes.

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MAINTENANCE 6. Reduce the engine to idle and drain the scale removing solution through the radiator drain c. At the same time, fill the radiator with running water for at least 40 minutes.

7. Stop the engine, let all the water flow out, close the radiator drain c, and fill the system with coolant.

8. Start the engine and after a few minutes check the fluid level in the radiator, and if necessary, add more coolant before tightening the cap b.

9. After draining the water from the expansion tank g, flush the tank’s inside and fill it with coolant until a level between the MIN and MAX marks is reached. Close the engine hood. ★ The cooling system must be flushed more frequently if the water used contains a high quantity of calcium salts, if the water is very hard.

f FUEL WATER SEPARATOR 1. Loosen the screw b and drain the contained liquid from the water separator, collect in a container with suitable capacity.

2. Loosen the central screw c, remove the bowl d, and filter element e. Clean inside of the pan.

3. Reinstall the filter e, bowl d, tighten screws c, b and bleed the fuel supply circuit, see FUEL FILTER on page 3-50. ★ If the filter element is excessively clogged or damaged, replace it.

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3-27

MAINTENANCE g FRONT WHEEL TOE IN This check must be done according to time intervals scheduled by the operator, since any abnormality regarding the wheel toe in is due to impacts or vibrations, depending on the type of surface which the machine works. Another reason for performing this check is to examine the front tires for excessive wear.

The machine has been designed with a toe in equal to 0 mm. Every adjustment must restore this value and must be carried out on tie rods b after loosening nuts c that lock them.

During this check and the relevant adjustment, it is advisable to also check conditions of the ball joints d. If considerable slack is observed, immediately replace them.

h PARKING BRAKE

During run in, check the efficiency of the parking brake after the first 500 hours of operation.

Check Check condition: Tire pressure as prescribed. Dry, compact road surface, with a 11° 20’ (1/5) grade. Machine in operating conditions.

1. Start the engine. Align the machine in a straight traveling position and proceed up the slope with 1/5 grade, with the bucket empty.

2. Stop the machine by applying the brake pedal, shift the directional control lever to the neutral position N, and stop the engine.

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MAINTENANCE 3. Apply the parking brake b, slowly release the brake pedal, and make sure that the machine does not move.

Adjustment 1. With the engine off and parked on flat and level ground, release the brake lever and rotate the lever end b by 2 or 3 clockwise turns to tighten.

2. Start the engine and check again.

i BRAKING EFFICIENCY ★ During run in, check the braking efficiency after first 100 hours of operation. Perform the check with the machine positioned on firm and flat ground, making sure that there are no people or obstacles in the vicinity.

Remark This check must be carried out after setting the work equipment in the travel or transport position, and engaging all safety locks.

1. Connect the brake pedals c with the pin b. Start the engine and release the parking brake.

2. Engage 2nd gear and forward gear.

3. Accelerate until reaching the maximum speed.

4. Press the brake pedals. The machine must brake smoothly on a straight line and the tension of the pedals must be constant. Otherwise, contact your distributor.

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3-29

MAINTENANCE j BRAKE PEDAL STROKE Perform this check when working on adjusting the brake pedal stroke to eliminate or prevent any problems.

To check and adjust the brake pedal stroke, proceed as follows: 1. Insert the connection pin b in order to couple the pedals.

2. By adjusting the end of stroke rubber pads c, position the pedals to measure 325 mm at A; secure the pads in this position.

3. Lower the pedals to measure 306 mm at A; adjust the position of the switches d by bringing them near the pedals and lock them.

4. Again, lower the pedals to measure 294 mm at A and adjust the brake pump rods e until they touch the pumping pistons, lock them in this position.

1) LOADER RETURN TO THE DIG POSITION The device for the return of the front bucket to the dig position automatically brings the front bucket to the loading position when it is lowered to the ground.

The sensor is positioned on the right bucket cylinder and determines the horizontal position of the bucket in relation to the ground after the bucket dump control has reached the end of its stroke and the electromagnet of the distributor rod has been operated.

The sensor must be positioned at a distance of 2 to 4 mm from the sliding rod.

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MAINTENANCE DEMOLITION HAMMER INTERVALS 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.

1! CHANGING THE HYDRAULIC OIL FILTER On new machines, change the filter after the first 100 to150 hours of operation and for the successive changes keep to the indications given in the table on the right.

If the machine contains synthetic biodegradable oil type HEES, the filter must be changed after the first 50 hours of operation.

1@ CHANGING THE HYDRAULIC OIL Change the hydraulic oil in the tank according to the intervals indicated in the table.

On machines containing synthetic biodegradable oil type HEES, change the oil after the first 500 hours of operation and for the successive changes keep to the indications given in the table.

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3-31

MAINTENANCE CHECKS BEFORE STARTING 1# VARIOUS CHECKS

Dirt with oil and/or fuel spread in the engine compartment near hot areas may cause fires and damage the machine.

Check to see if there are frequent leaks and perform any necessary repairs immediately. If this occurs repeatedly, contact your distributor.

Before starting the engine, check the following: 1. Check for loose screws or nuts.

2. Check for oil, fuel or coolant leakage.

3. Check for worn equipment.

4. Check condition of wheel rims, and condition and wear of the tires.

5. Check condition and efficiency of instruments and warning lights on the dashboard, working lights and direction indicators.

The other general checks concern safety, and functionality: 1. Soundness of the safety belt.

2. Clearness and legibility of the warning decals.

3. Cleanliness of the ladders and hand rails used to reach the drivers seat, cleanliness inside the operator’s compartment.

1$ FUEL LEVEL

When refueling, avoid spilling fuel to prevent any risk of fire.

If some fuel should inadvertently be spilled, clean the dirty area immediately. Fuel is flammable; neither use exposed flames, nor smoke while refueling. Place the fuel nozzle into the filler. Do not fill the tank completely, leave space for fuel expansion.

To check the fuel level, use the indicator b on the dashboard.

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MAINTENANCE Remark It is advisable to refuel after work, in order to avoid the formation of condensation. After refueling, tighten the filler cap c thoroughly and lock the tank.

1% COOLANT LEVEL

Do not remove the radiator cap; the coolant must be checked with the engine cold, through the expansion tank. The upper MIN and MAX marks indicate the expansion level of the coolant at operating temperature.

The coolant level can be checked in the expansion tank b. With the engine cold, the coolant level must be between the MIN and MAX lower marks. The check must be performed through the hole positioned on the right side of the engine hood and the coolant level must be above the MIN lower mark.

If the level is near the lower limit of the MIN mark, fill the tank with coolant, and if the level decreases considerably and constantly, check the radiator, engine, and radiator body for leaks. Also check fluid level in the radiator. The expansion tank b can be reached after opening the engine hood.

1^ ENGINE OIL LEVEL

After the machine is stopped, the engine is very hot. Let the engine cool down before performing any check. Hot engines may cause burns. If it is necessary to check the oil level during or soon after work, stop the engine and wait for 15 minutes before checking.

The dipstick b can be reached after opening the engine hood.

The check must be performed with a cold engine and the machine located on level ground.

The oil level can be checked on the graduated dipstick b and must be between MIN and MAX marks. If the level is near the MIN mark, top off with oil as prescribed in the lubricant chart.

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MAINTENANCE 1& HYDRAULIC SYSTEM OIL LEVEL

The oil level in the hydraulic system must be checked with cold oil and the machine positioned on level ground and in lubricating position. If it is necessary to top off, stop engine and then eliminate the residual pressures present in the work equipment, move the controls more than once and in the tank by slowly loosening filler cap. When adding oil, do not exceed the MAX level. This would damage the hydraulic system and cause oil to flow out. If a constant or abnormal decrease of the oil level is observed, thoroughly check the hydraulic system, the pistons and pump for leaks.

The oil level must be visible through the sight gauge b positioned on the tank and must be filled between MIN and MAX marks.

If level is near the MIN mark, top off by adding the hydraulic oil through filler c, see FUEL COOLANT AND LUBRICANTS on page 3-6. Reinstall the filler cap.

1* DRAINING WATER SEPARATOR

The fuel is flammable; do not use exposed 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 condensation and must be done with a full tank, in order to prevent air from entering the fuel supply system.

Condensation must be drained at the end of work, before the engine has completely cooled down, in order to prevent freezing if the temperature gets very low.

The water separator can be reached after opening the engine hood. Condensation is drained by loosening plug b and waiting until only clear diesel fuel flows out.

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MAINTENANCE EVERY 10 HOURS OF OPERATION 1( LUBRICATION POINTS

Clean the grease fittings before attaching the grease pump. After lubrication, remove all the contaminated grease that may have spread out of the fittings. If the machine is used in difficult conditions, perform these operations more frequently than usual.

This maintenance operation must be done with front bucket resting on the ground, and the backhoe equipment completely extended and resting on the ground. Use the prescribed grease, pump grease, see FUEL COOLANT AND LUBRICANTS on page 3-6.

Loader Lube Points

b c d e

Tie rod - bucket coupling pin.....................

2 POINTS

Bucket fulcrum pin ....................................

2 POINTS

Lever fulcrum pin ......................................

2 POINTS

Tie rod lever coupling pin..........................

2 POINTS

f g h i j 1) 1!

1!

Bucket cylinder head pin...........................

2 POINTS

Lift cylinder head pin.................................

2 POINTS

Lift cylinder base pin .................................

2 POINTS

Boom fulcrum pin......................................

2 POINTS

Bucket cylinder base pin...........................

2 POINTS

MP bucket fulcrum pin ..............................

2 POINTS

MP bucket cylinder base pin.....................

2 POINTS

MP bucket cylinder head pin.....................

2 POINTS

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3-35

MAINTENANCE Backhoe Lube Points STANDARD ARM

1# 1$ 1% 1^ 1& 1* 1( 2) 2!

2@

Stabilizer cylinder pin.......................

2 POINTS

Stabilizer arm fulcrum pin ................

2 POINTS

Boom swing cylinder piston pin .......

4 POINTS

Boom swing fulcrum pin ..................

2 POINTS

Stabilizer pad pin .............................

2 POINTS

Stabilizer cylinder pin.......................

2 POINTS

Boom fulcrum pin ............................

2 POINTS

Boom swing cylinder head pin.........

2 POINTS

Lift cylinder piston pin ......................

1 POINT

Arm cylinder piston pin ....................

1 POINT

2$ 2% 2^ 2& 2* 2( 3) 3!

3@ 3#

Arm cylinder rod pin.........................

1 POINT

Arm fulcrum pin ...............................

1 POINT

Bucket cylinder piston pin................

1 POINT

Bucket cylinder rod pin ....................

1 POINT

Tie rod lever coupling pin ................

2 POINTS

Tie rod bucket coupling pin..............

2 POINTS

Lever fulcrum pin .............................

1 POINT

Bucket fulcrum pin ...........................

1 POINT

Telescopic cylinder piston pin ..........

1 POINT

Telescopic cylinder rod pin ..............

1 POINT

2# Lift cylinder rod pin .......................... 1 POINT OFFSET BOOM

3$ Knuckle at boom pin...................................

3% Knuckle at arm pin .....................................

1 POINT

3^ Offset cylinder rod pin ................................

3& Offset cylinder piston pin ............................

1 POINT

3-36

1 POINT

1 POINT

WB150AWS-2N

MAINTENANCE FIRST 50 HOURS OF OPERATION 2) HEES OIL TYPE The following maintenance operation must be performed after the first 50 hours of operation, together with maintenance operations to be initiated EVERY 50 HOURS. ★ HYDRAULIC OIL FILTER CHANGE For further details on the various maintenance operation, see EVERY 500 HOURS OF OPERATION on page 3-48.

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3-37

MAINTENANCE EVERY 50 HOURS OF OPERATION ★ Perform the following operations together with those to be initiated every 10 HOURS:

2! RADIATOR FLUID LEVEL

Perform this check with the machine parked on level ground and loader arm raised with the safety lock engaged. Do not remove the radiator cap when the fluid is hot, since the fluid may be sprayed out of the radiator and cause burns. Loosen the cap slowly to release the pressure before removing it.

The radiator cap can be reached after opening the engine hood.

Remove the cap b and make sure that the fluid is very near the filling hole.

Remark If level of fluid in the radiator is low and the expansion tank is filled with coolant, check cap tightness and make sure that there are no air leaks from the coupling that connects the radiator and expansion tank. If problem persists, contact your distributor.

2@ BRAKE SYSTEM OIL LEVEL The brake reservoir b can be reached after opening the engine hood. This is a visual check and the reservoir must be topped off with the prescribed fluid until reaching the MAX mark, see FUEL COOLANT AND LUBRICANTS on page 3-6.

Remark Use new oil only. If constant and considerable leakages are observed, it is advisable to contact your distributor to have the system checked and necessary repairs made.

2# DRIVE SHAFTS Lubrication must be done after carefully cleaning the grease fittings, by attaching the grease pump and using the prescribed grease, see FUEL COOLANT AND LUBRICANTS on page 3-6.

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MAINTENANCE Once lubrication has been completed, make sure that all the points have been lubricated and remove the contaminated grease that may have spread out of the joints.

2$ FRONT AND REAR AXLE JOINTS AND FRONT PIVOT Lubrication points b of the wheel joints are indicated and it is important to remember that they are located in symmetrical positions, while the front pivot is lubricated by means of a grease fitting c positioned on the frame.

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3-39

MAINTENANCE Lubrication must be done after carefully cleaning the grease fittings, by attaching the grease pump and using the prescribed grease, see FUEL COOLANT AND LUBRICANTS on page 3-6.

Once lubrication has been done, remove the contaminated grease that may have spread out of the joints and central coupling.

2% TIRE PRESSURE

Inflate the tires only after positioning them in a protective cage. To inflate the tire, stand beside the external belt. Do not exceed the pressures prescribed.

This check is indispensable to preserve the tires, keep them efficient over time and make them last longer.

The correct pressures are indicated in the specifications section, see SPECIFICATIONS on page 4-2.

While checking the pressure, check conditions of the tread and sidewalls.

2^ ELECTRICAL SYSTEM

It the fuses are corroded, oxidized or not perfectly held in their seat, replace them only with fuses having the same capacity. Before changing a fuse, make sure that the ignition key is in the OFF position. If there are signs of short circuits on the cables, find the causes and repair them; always contact your distributor for troubleshooting.

Make sure that there are no disconnected cables or signs of short circuit in the electrical system. Make sure that all the cables are securely tightened to their respective terminals. Tighten any loose cables.

Check the following:

3-40

A

Battery

B

Starter

C

Alternator

WB150AWS-2N

MAINTENANCE FIRST 250 HOURS OF OPERATION Perform the following maintenance after the first 250 hours, together with those to be initiated EVERY 250 HOURS.

2& FRONT AXLE ................................................... OIL CHANGE 2* REAR AXLE ..................................................... OIL CHANGE 2( HYDRAULIC TRANSMISSION ........................ OIL CHANGE 3) HYDRAULIC TRANSMISSION ........... OIL FILTER CHANGE 3! ENGINE VALVE CLEARANCE........... CHECK AND ADJUST 3@ HYDRAULIC OIL ............................DRAIN FILTER CHANGE For details on the various maintenance operations; See EVERY 500 HOURS OF OPERATION on page 3-48.

See EVERY 1000 HOURS OF OPERATION on page 3-53.

For checks and adjustments, contact your distributor.

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3-41

MAINTENANCE EVERY 250 HOURS OF OPERATION ★ Perform the following operations together with those to be initiated at 10 and 50 HOURS:

3# FAN BELT TENSION The fan belt can be reached after opening the engine hood, see ENGINE HOOD on page 2-71.

The test is manual: press the belt b with your thumb on the indicated point with a force equal to about 98 N; the resulting deflection must be about 10 to 15 mm. If the deflection exceeds this value, loosen the bolt c that fastens the alternator d and, with a lever inserted between the engine block and casing, move the alternator. Lock the bolt and check again.

A

Fan pulley

B

Alternator pulley

★ If the belt is worn, replace it and check the tension again after a few hours of operation.

3$ A/C COMPRESSOR BELT TENSION

The coolant used in the air conditioning system is very dangerous. If it is sprayed into the eyes or in case of contact with the skin, it may cause blindness or frostbite. Furthermore, to avoid any explosion, do not generate sparks and do not use open flames near the air conditioner. The adjustment of the belt tension is a mechanical operation and must be carried out without working on the air conditioning system.

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MAINTENANCE A

Compressor pulley

B

Idle pulley

C

Engine pulley

The compressor belt can be reached after opening the engine hood, see ENGINE HOOD on page 2-71.

The check is manual and consists in exerting pressure on the belt b with a thumb at the center of the section between the compressor c and the pulley d.

If the pressure exerted is about 10 kg, the resulting deflection must be 7 to 10 mm. When the belt is still new, the resulting deflection must be 4 to 6 mm.

If the deflection exceeds these values, loosen the bolt e that fastens the cam f. Apply a tube on the end g of the cam to restore the correct the belt tension. Lock the cam in this position with the bolt.

Remark If the belt is worn or in case of doubt on its condition, change it and check the tension again after a few hours of operation.

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3-43

MAINTENANCE 3% RADIATOR OUTSIDE

If compressed air, steam or water are directed against a person, they may cause injuries. Always wear an eye shield and safety shoes.

1. To clean the outside of the radiator it is first necessary to remove the guard b positioned on the front of the engine hood.

To remove the guard, remove the relevant bolts c.

2. The outside of the radiators must be cleaned with a jet of compressed air and, if necessary, with a low pressure water or steam washing cycle; the specific products available on the market can certainly be used, provided that the instructions given on the package are followed and that the washed parts are carefully dried at the end of the operations. After the washing cycle, put back the guard b with the relevant hardware c. ★ Do not use products containing a slight quantity of oily substances, since these facilitate the adhesion of dust, which affects the heat exchange adversely. Clean the outside of the radiators whenever the unit is dirtied, even if accidentally, with oil, diesel oil, greasy or oily substances.

3^ CONDENSER OUTSIDE

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 b must be cleaned at the same at as the radiators. The condenser b must be cleaned with a jet of compressed air and, if necessary, with a low pressure water or steam washing cycle; the specific products available on the market can certainly be used, provided that the instructions given on the package are followed and that the washed parts are carefully dried at the end of the operations. ★ Do not use products containing even a slight quantity of oily substances, since these facilitate the adhesion of dust, which affects the heat exchange adversely. ★ Carry out this operation whenever the condenser is dirty, even if accidentally, with oil, diesel fuel, greasy or oily substances. To clean the radiator, rotate the condenser b on the lower pins. If the machine is used in dusty places, clean the condenser more frequently, in order to prevent the fins from clogging.

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MAINTENANCE 3& BATTERY ELECTROLYTE LEVEL

Check the level with the machine parked on flat ground.

Check the level only after stopping the engine and if necessary add distilled water only before starting work. Always wear safety goggles and waterproof gloves. To prevent gas explosions, do not use exposed flames. Do not smoke. Avoid producing sparks due to short circuits. The battery electrolyte is dangerous; if it comes in contact with the eyes or skin, rinse with plenty of water and consult a doctor without delay.

The battery b can be reached after removing the cover c fastening bolts d. The electrolyte level in each cell must be about 6 mm above the plate edge; if necessary, add distilled water only. To reach the fill holes of the cells, first remove the guard e. If the level is low because some fluid has been spilled, add sulfuric acid, after having diluted it until reaching the concentration suitable for the ambient temperature. After finishing, reinstall the guard and cover with fastening bolts. ★ It is advisable to add distilled water before starting work, in order to prevent freezing. Before reinstalling the cell plugs, make sure that the breather holes are not clogged. Make sure that the connection terminals are not oxidized; if necessary, clean them and cover them with anti oxidation grease.

3* FRONT AXLE OIL LEVEL Differential This visual check serves to verify if the lubricant reaches the level hole b. If necessary, top off using the prescribed oil, see FUEL COOLANT AND LUBRICANTS on page 3-6.

The level hole b must also be used as the fill hole.

Planetary Conduct this check with each reduction gear positioned with the plug on the horizontal axis. If necessary, move the machine slightly until the specific position for a precise check is reached.

This visual check serves to verify if the lubricant reaches the level hole c. If this does not occur, add the prescribed oil, see FUEL COOLANT AND LUBRICANTS on page 3-6.

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3-45

MAINTENANCE 3( REAR AXLE OIL LEVEL Differential This check is visual and serves to verify if the lubricant reaches the level hole b; if necessary, top off using the prescribed oil, see FUEL COOLANT AND LUBRICANTS on page 3-6.

The level hole b must be used also as the fill hole.

Planetary The check must be carried out on each reduction gear positioned with the plug on the horizontal axis. If necessary, move the machine slightly until reaching the specific position for a precise check.

This check is visual and serves to verify that the lubricant reaches hole c; if this does not occur, top off using the prescribed oil, see FUEL COOLANT AND LUBRICANTS on page 3-6.

4) TRANSMISSION OIL LEVEL

Level must be checked with the engine running and transmission oil at operating temperature; be very careful, in order to avoid burns. If it is necessary to add oil, stop engine before opening the engine hood. Prevent possible injury from unexpected machine movement. Never rely on directional control lever alone to keep machine from moving. It can unexpectedly roll or move under power, resulting in death or serious injury. Always engage the parking brake to hold the machine.

The dipstick b can be reached by opening on the engine hood.

The level must be checked with the engine running at 800 to 1000 rpm and with the transmission oil at operating temperature.

The oil level must be within the maximum level mark.

To add oil, use the dipstick b filler tube and the prescribed oil, see FUEL COOLANT AND LUBRICANTS on page 3-6.

4! WHEEL LUG NUT TORQUE This check is used to verify that the torque of the wheel lug nuts on the hubs are correct.

The lug torque must be checked by means of a torque wrench b set according to the values indicated, see SPECIFICATIONS on page 4-2. ★ Do not Increase the specified driving torque and keep it within the prescribed ranges. When the driving torque must be checked, do not lubricate the thread.

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MAINTENANCE FIRST 500 HOURS OF OPERATION ★ Only for machines in which synthetic biodegradable oil type HEES is used. ★ The following maintenance operation must be performed after the first 500 hours of operation, together with maintenance operations to be initiated at 500 HOURS.

4@ CHANGE HYDRAULIC OIL AND CLEAN SUCTION FILTER 4# HYDRAULIC OIL TANK For further details on the various operations, see EVERY 2000 HOURS OF OPERATION on page 3-57.

WB150AWS-2N

3-47

MAINTENANCE EVERY 500 HOURS OF OPERATION ★ Perform these operations together with those initiated every 10, 50 and 250 HOURS.

4$ ENGINE OIL

Change the oil with machine parked on level ground and raised loader arm with the safety lock engaged. After machine has been operated, the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40 to 45°C before draining the oil. Oil that may be spilled during the change makes the ground slippery, therefore, use anti-slip shoes and immediately remove any trace of oil from the floor. Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti-pollution regulations in force.

When changing the oil, also change the filter, see ENGINE OIL FILTER on page 3-49.

Proceed as follows: 1. Open the engine hood.

2. Remove the oil pan drain plug b. Collect the used oil in a container of sufficient capacity.

3. While the oil flows out, remove the filler cap c, so that the oil can flow freely. Change the engine oil filter.

4. Tighten the engine oil pan drain plug b, and add the exact quantity of new oil, using the dipstick d to make sure that oil reaches the MAX level.

5. Reinstall the filler cap c. Start the engine, and let it run for 5 minutes and then shut it down. Check the oil level again and add oil if necessary.

6. Close the engine hood. ★ Use oil suitable for the ambient temperature, see FUEL COOLANT AND LUBRICANTS on page 3-6.

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MAINTENANCE 4% ENGINE OIL FILTER

Immediately following machine operation, engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40 to 45°C before draining the oil.

Oil that may be spilled during changes makes the ground slippery, use anti slip shoes and immediately remove any trace of oil from the floor. Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

Replace the oil filter every time the oil is changed.

1. Unscrew and remove the old filter b, using the special wrench that is provided. Clean contact surface between the gasket and filter support c.

2. Fill the new filter with clean engine oil, lubricate gasket, and carefully thread it on until hand tight. Give the filter another half turn by hand.

Start the engine. Make sure that there are no leaks and that the oil pressure warning light goes out. Do not use the wrench to tighten the filter. The filter may get damaged and cause an oil leak.

4^ HYDRAULIC SYSTEM OIL FILTER

Following machine operation, the hydraulic oil is very hot; let it cool down until it reaches a temperature of 40 to 45°C before changing it. The hydraulic system is pressurized; loosen filling cap slowly to release the residual pressure. Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force

The filter is positioned in the hydraulic system drain outlet and blocks any metal particles that come off various components due to wear.

The filter can be reached after removing the bolts c, and upper platform b.

1. Remove the filler cap d. Remove the bolts e from the filter cover f, and remove the cartridge g and filter casing h.

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3-49

MAINTENANCE 2. Carefully clean the filter casing h, making sure that the by pass valve i, and casing gasket j are in perfect condition.

3. Clean the magnetic rings 1) that are positioned on the cover to attract metal particles.

4. Change the cartridge g.

5. Reassemble the unit by proceeding in the reverse order, and make sure that the cover f and gasket 1! are in perfect condition, and are housed in the cover seat.

6. Reinstall the upper platform b and secure it the bolts c.

★ Hydraulic oil in the machines equipped with a demolition hammers deteriorates more rapidly than the oil of machines used for simple digging operations. On new machines, replace the filter after the first 100 to150 hours of operation and for successive replacements, follow the schedule on replacement interval table. ★ If the machine contains synthetic biodegradable oil type HEES, the filter must be replaced after the first 50 hours of operation.

4& FUEL FILTER

Replace the filter element after work, when engine has cooled down to 40 to 45°C. When these operations are carried out, fuel may be spilled; clean the dirty areas immediately, in order to prevent any risk of slipping or fire. Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

The fuel filter and the fuel pump can be reached after opening the engine hood.

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WB150AWS-2N

MAINTENANCE A90002 to A90008 FUEL FILTER 1. Clean the external surfaces of the unit and then unscrew and remove the old filter b. Clean the inside of the head c.

2. Lubricate the gasket of new filter and tighten thoroughly. Give it another half turn by hand. Bleed the fuel supply circuit.

BLEEDING THE CIRCUIT 1. Fill the tank. Turn the ignition switch to the ON position. Loosen the drain screw d of the filter head c. Completely unscrew the fuel pump f and knob e. Operate the knob e until fuel without air bubbles flows out of the filter head.

2. Tighten the drain screw d. Press the knob e and tighten it completely. Start the engine. ★ If fuel does not flow out when the fuel pump lever is operated, rotate the drive shaft giving it one turn. Do not let the starter run for more than 15 seconds. Wait at least 15 seconds before repeating the procedure. If the engine starts regularly and then stops or runs irregularly, check for air in the system.

If so, check the fuel filter, water separator, and fuel pump for leaks. After all the fuel has run out, bleed the system.

A90009 and Up FUEL FILTER 1. Clean the external surfaces of the unit and then remove the old filter b by means of the special wrench provided. Clean the inside of the head c.

2. Lubricate the gasket of the new filter and tighten. Given another half turn by hand. Bleed the fuel supply circuit.

BLEEDING THE CIRCUIT After filling the tank, turn the ignition key to the I position and wait about 15 to 20 seconds, as to bleed the fuel circuit. ★ After bleeding the circuit, turn the ignition key to crank position for a few seconds and wait at least two minutes before starting the engine. If the engine starts regularly and then stops or works irregularly, check if there is air in the circuit; if so, check the fuel filter and the water separator for leaks.

When all the fuel in the tank has been consumed, bleed the circuit by proceeding as described above and repeat the operation at least twice.

WB150AWS-2N

3-51

MAINTENANCE 4* FUEL TANK

When draining the fuel tank, avoid spilling fuel, since this may cause fires. If some fuel is accidentally spilled, clean the dirty area immediately, in order to prevent it from getting slippery and to avoid fires.

This operation serves to remove impurities and condensation from the tank. Remove the lower plug b and wait until clean fuel flows out.

Remark The tank must be drained before starting the engine, with temperatures exceeding 0°C; or when below 0°C, the tank must be drained at the end of work or with the machine at operating temperature, to prevent condensation from freezing. Any condensation and impurities that has accumulated inside the tank must be eliminated before refueling.

4( HYDRAULIC OIL TANK

Stop the engine, and place machine in the correct position to perform maintenance operations. Eliminate residual pressures from the equipment, by moving the controls more than once, and from the tank, by slowly loosening the filler cap.

Let the oil cool down until it reaches 40 to 45°C before performing any maintenance. Immediately clean any area dirty with oil.

This operation serves to let condensation, accumulated on the tank bottom, to flow out of the tank itself. Perform the following operations in the given sequence: 1. Remove the bolts b and platform c. Loosen the filler cap d to release any residual pressure in the tank.

2. Remove the drain plug e and let condensation flow out of the tank completely. Reinstall the filler cap d and platform c. ★ Draining of the tank must be done at temperatures exceeding 0°C, before starting the engine. When temperature is below 0°C, the oil tank must be drained at the end of work, or when the temperature of the machine is sufficiently high, to prevent condensation from freezing and allow the oil to flow out of the tank.

3-52

WB150AWS-2N

MAINTENANCE EVERY 1000 HOURS OF OPERATION ★ Perform these operations together with those initiated every 10, 50, 250, and 500 HOURS.

5) FRONT AXLE OIL

Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

Perform this operation with the machine positioned on level ground and at operating temperature, so that the oil can be easily drained, which facilitates the elimination of any suspended solid particles.

Differential 1. Remove the drain plug C and let the oil flow out completely.

Collect it in a container with suitable capacity. While the oil flows out, remove the plug B. 2. Once the oil has been drained, reinstall the plug C and pour oil of the prescribed type through the fill hole b, until the level corresponding to the lower edge of the hole itself is reached, see FUEL COOLANT AND LUBRICANTS on page 3-6. Reinstall the plug b.

Planetary 3. Move the machine until the plug d is in the lowest position on the vertical axis.

4. Remove the plug d and let the oil flow out, Collect it into a container with suitable capacity.

5. Once the oil has been drained, move the machine until the plug d, which also serves as level indicator, is positioned on the horizontal axis.

6. Pour oil of the prescribed type through the hole until the lower edge of the hole itself is reached, see FUEL COOLANT AND LUBRICANTS on page 3-6. Reinstall the plug d.

Remark Move the machine both forward and backward. Stop the machine to check the oil level again. Always use oil of the proper type, see FUEL COOLANT AND LUBRICANTS on page 3-6.

WB150AWS-2N

3-53

MAINTENANCE 5! REAR AXLE OIL

Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

Perform this operation with the machine positioned on level ground and at operating temperature, so that the oil becomes fluid and can be easily drained, which facilitates elimination of any suspended solid particles.

Differential 1. Remove the drain plug c and let the used oil flow out completely, collect it in a container with suitable capacity. While the oil flows out, remove the plug b.

2. Once the oil has been drained, reinstall the plug c and pour oil of the prescribed type through hole b, until the level corresponding to the lower edge of the hole itself is reached, see FUEL COOLANT AND LUBRICANTS on page 3-6. ★ With this operation both axle shafts are filled with oil; before checking the level and putting back the plug, wait a few minutes, in order to permit the uniform distribution of oil.

3. Install plug b.

Planetary 1. Move the machine until the drain plug d is in the low position on the vertical axis.

2. Remove the plug d and let the used oil flow out, collect it into a container with suitable capacity.

3. After draining the oil, move the machine until the plug d, that also serves as the level indicator, is positioned on the horizontal axis.

4. Pour oil of prescribed type through the hole until it reaches the lower edge of the hole itself, see FUEL COOLANT AND LUBRICANTS on page 3-6.

5. Reinstall the plug d.

Remark Move the machine both forward and backward and then stop it. Check the levels again. Always use oil of the prescribed type, see FUEL COOLANT AND LUBRICANTS on page 3-6.

3-54

WB150AWS-2N

MAINTENANCE 5@ TRANSMISSION OIL

Perform this operation with the machine parked on level ground and the raised loader boom with engaged the safety lock. Hydraulic transmission oil must be drained at operating temperature, which is very high, and may cause serious burns, wear insulating gloves, goggles and safety shoes. Immediately clean any area dirty with oil. Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

When changing the transmission oil, also change the filter, see TRANSMISSION FILTER on page 3-55.

1. Open the engine hood.

2. Remove the drain plug b and let the oil flow into a suitable container.

3. Carefully remove the filter and replace.

4. Reinstall the plug b and pour oil until it reaches the MIN level on the stick c, see FUEL COOLANT AND LUBRICANTS on page 3-6.

5. Start the engine and let it idle to fill the converter and internal system. While the engine is at idle, continue to add oil until the MIN level is reached again.

6. When oil reaches a temperature of 50°C, continue to add oil until it reaches the MAX mark.

7. Close the engine hood.

5# TRANSMISSION FILTER

After operating machine, the transmission unit becomes very hot and may cause burns. Let the machine cool down before changing the filter. Oil that may be spilled during replacement of the filter may cause the floor to become slippery: use anti slip shoes and immediately remove any trace of oil from the floor and transmission unit. Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

WB150AWS-2N

3-55

MAINTENANCE ★ Change the filter every time the transmission oil is changed.

1. Raise the front mat and remove the cover b. Unscrew and remove the filter c.

2. Clean the contact surface between the gasket and the filter support d.

3. Lubricate the gasket, fit it in its seat and install the filter until it touches the gasket. Give it another half turn by hand.

4. Start the engine, let it idle and let the oil warm up until it reaches operating temperature.

5. Add oil until it reaches the MAX mark on the dipstick e. Always fill with proper oil, see FUEL COOLANT AND LUBRICANTS on page 3-6.

6. Reinstall the cover b.

5$ ENGINE VALVE CLEARANCE ★ Since the check and adjustment of the engine valve clearance requires the use of special tools, have these operations performed by your distributor.

3-56

WB150AWS-2N

MAINTENANCE EVERY 2000 HOURS OF OPERATION ★ Perform these operations together with those to be initiated every 10, 50, 250, 500, and 1000 HOURS.

5% HYDRAULIC SYSTEM OIL AND SUCTION FILTER ★ On machines containing synthetic biodegradable hydraulic oil type HEES, replace oil after the first 500 hours of operation and successively every 2000 hours, or at least once a year.

After stopping engine, with the machine positioned so that maintenance can be performed, release residual pressures from the work equipment system, by operating the controls more than once, and from the tank, by slowly loosening the filler cap. Let the oil cool down until it reaches 40 to 45°C before performing any maintenance. Immediately clean any area dirty with oil. Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

The filter can be reached after removing the bolts c and platform b.

1. Remove the filler cap d. Remove the drain plug e and let the oil flow out. Collect it in a container with suitable capacity.

2. Remove the upper flange f, filter cartridge g, and filter casing h.

3. Remove the suction strainer i, complete with gasket j and clean it with a light solvent. ★ Carefully check the suction strainer and if it is not in perfect condition, replace it.

4. Reinstall the filter i complete with gasket j.

5. Replace the filter cartridge g and reassemble the whole unit, see HYDRAULIC SYSTEM OIL FILTER on page 3-49.

6. Reinstall the drain plug e and fill the oil tank with the prescribed oil until it reaches the proper level at 1). For proper oil, see FUEL COOLANT AND LUBRICANTS on page 3-6.

WB150AWS-2N

3-57

MAINTENANCE 7. Raise the front mat and remove cover 1!.

8. Loosen the bleeder plug 1@ located on the hydraulic pump, until no air bubbles can be observed in the oil that flows out.

Tighten the bleeder plug 1@ and reinstall the cover 1!.

9. Reinstall the filler cap d. Start the engine and operate the machine making each cylinder move several times in order to bleed the system.

10. Stop the machine in the maintenance position, check the oil level again and if necessary, add oil. Always use oil of the proper type, see FUEL COOLANT AND LUBRICANTS on page 3-6.

11. Put back the upper platform b with relevant hardware c. ★ Do not start engine with an empty tank, since this would certainly damage the pump.

3-58

WB150AWS-2N

MAINTENANCE ★ Hydraulic oil of the machines equipped with demolition hammer deteriorates more rapidly than oil of the machines used for simple digging operations. ★ Perform oil changes as scheduled on the accompanying table.

5^ RADIATOR COOLANT

After the machine has been operated, coolant is very hot and under pressure and it may cause serious burns. Let the engine cool down until it reaches about 40 to 45°C before changing the coolant. Slowly loosen radiator cap, in order to release the residual pressure. Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

The following operations refer to changing permanent coolants, if the coolant is water or water with antifreeze, which are used according to the season, it is necessary to flush the cooling system in order to eliminate any deposits.

1. Remove the front guard b and hardware c. Open the engine hood.

2. Loosen and remove the upper radiator cap d.

WB150AWS-2N

3-59

MAINTENANCE 3. Open the radiator drain valve e, loosen the drain valve f on the filter carrier head. The coolant will flow out, collect it in a container with suitable capacity.

Be extremely careful when performing this maintenance operation. Since the engine must be running, one operator must remain on the machine and another operator helping after they decide on words and signals to use. After work, when the machine is stopped, the coolant is very hot and under pressure and may cause serious burns. Let the engine cool down until it reaches approximately 40 to 45°C before starting the flushing operations. Slowly loosen the radiator cap, to release residual pressure. Engage all of the work equipment safety locks. Apply the parking brake and do not move the gear shift lever. Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

★ Whenever changing from water to using antifreeze fluids, and vice versa, it is necessary to flush the system in order to eliminate either oxide deposits or limestone deposits.

4. With the fluid still warm, open the radiator drain cock c, loosen the drain valve d positioned on the filter carrier head and loosen the radiator cap b. Let all the fluid flow out. Tighten the valve d on the filter carrier head at engine and close the radiator drain cock c.

5. Pour a high quality scale remover into the radiator, in doses recommended on the package, capacity of the cooling system; 14 l. Fill the radiator with water. Start the engine and let it run at high rpm for about 15 minutes.

6. Reduce the rotation speed to idle and drain the scale removing solution through the radiator drain cock c. At the same time, fill the radiator with running water for at least 40 minutes.

7. Stop the engine, let all the water flow out, close the radiator drain cock c, and fill the system with coolant.

8. Start the engine and after a few minutes check the fluid level in the radiator, and if necessary, add more coolant before tightening the cap b.

9. After draining the water from the expansion tank e, flush the tank’s inside and fill it with coolant until a level between the MIN and MAX marks is reached.

10. The cooling system must be flushed more frequently if the water used contains a high quantity of calcium salts, if the water is very hard.

3-60

WB150AWS-2N

MAINTENANCE 11. Close the radiator drain valve c, tighten the valve d on the filter carrier head, and fill the radiator with new coolant, see FUEL COOLANT AND LUBRICANTS on page 3-6.

12. Start the engine and let it idle for a few minutes; check the coolant level again. Add coolant, if necessary. Reinstall the upper radiator cap b.

13. Fill the expansion tank e until the maximum level is reached.

14. Close the engine hood and install the front guard.

5& BRAKE SYSTEM OIL

Oil spilled on the floor may cause it to become slippery; immediately clean any dirty area. Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all EPA and/or anti pollution regulations in force.

Before changing the brake system oil, it is advisable to apply the brake a few times in order to warm the oil to speed up the draining. Changing the oil and bleeding the brake system must be done with the machine positioned on level ground with the parking brake set. To drain the oil and bleed the system, proceeding as follows: 1. Attach a small hose, for collection of the oil, to the drain screws b and loosen them.

2. Open the engine hood and remove the cap c from the tank d.

3. Operate the tandem brake pedals, connected to each other, until the oil in the tank d runs out.

4. Fill the tank d with new oil and keep pumping until the used oil, about 0.8 l, has been completely purged, Bleed the residual air. For details of the oil to be used, see FUEL COOLANT AND LUBRICANTS on page 3-6.

5* ALTERNATOR AND STARTER ★ For any inspection and/or repair, contact your distributor. If the engine is started frequently, have inspection done every 1000 hours of operation.

WB150AWS-2N

3-61

MAINTENANCE 5( A/C SYSTEM COOLANT

The coolant used in the air conditioning system is very dangerous. If it is sprayed into the eyes or in case of contact with the skin, it may cause blindness or frostbite. Furthermore, to avoid any explosion, do not generate sparks and do not use naked flames near the air conditioner. Oils, filters, coolants and batteries are considered special waste and must be recovered and disposed of according to all EPA and/or anti pollution regulations in force. The maintenance of the air conditioning system must be carried out exclusively by specialized personnel.

Specific equipment is required to check the coolant; have this maintenance operation carried out only by specialized personnel and for this purpose contact your distributor.

3-62

WB150AWS-2N

MAINTENANCE EVERY 4000 HOURS OF OPERATION ★ Perform these operations together with those initiated every 10, 50, 250, 500, 1000 and 2000 HOURS.

6) A/C DEHYDRATING FILTER

The coolant used in the air conditioning system is very dangerous. If it is sprayed into the eyes or in case of contact with the skin, it may cause blindness or frostbite. Furthermore, to avoid any explosion, do not generate sparks and do not use naked flames near the air conditioner. Oils, filters, coolants and batteries are considered special waste and must be recovered and disposed of according to all EPA and/or anti pollution regulations in force. Have the filter changed only by specialized personnel and for this purpose contact your distributor.

The filter b must be replaced every 4000 hours of operation or every 2 years, whichever occurs first. The filter must also be replaced in case of operations carried out on the air conditioning system.

6! A/C COMPRESSOR Specific equipment is required to check the operating conditions of the compressor b; have the compressor checked only by specialized personnel and for this purpose contact your distributor.

WB150AWS-2N

3-63

MAINTENANCE LONG TERM STORAGE BEFORE STORAGE

When draining the fuel, do not smoke or have exposed flames near machine. Place a container under the machine to collect fuel and prevent it from spreading. If some fuel is spilled, clean the dirty surface immediately.

★ To protect the cylinder rods when the machine is not used, position the work equipment as shown. This serves to prevent the cylinder rods from rusting.

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.

2. Insert supports under the axles to avoid overloading them, and to avoid any deformation of tire sidewalls.

3. Drain and change all fluids of the hydraulic system and lubricants; axles, reduction gears, converter, and engine.

4. Change all filtering elements; air cleaner, engine oil, hydraulic system, diesel.

5. Drain the coolant and replace it with a corrosion inhibitor, permanent fluid.

6. Drain the fuel and fill the tank with at least 10 l of special washing and protecting fuel.

3-64

WB150AWS-2N

MAINTENANCE 7. Let the engine run for about 10 minutes, to eliminate the residual fuel from the filters, injection pump, and entire fuel supply system. This procedure prevents the injection pump and injectors from seizing. Stop the engine and refuel with diesel fuel.

8. Remove the battery, check the electrolyte level and make sure that the battery charge is sufficient. Store the battery in a room with suitable temperature and periodically recharge it.

9. Grease the hydraulic cylinder rods.

10. Seal the end of the exhaust pipe and fuel tank cap.

11. Move the machine controls to neutral and engage the safety locks of the equipment controls.

12. Hang a warning notice on the steering wheel to indicate condition of the machine.

13. Lock the cab doors, fuel tank cap, and engine hood.

DURING STORAGE

When carrying out rust prevention treatment while the machine is indoors, open doors and windows to increase ventilation and avoid poisoning by gas.

★ Start engine and move the machine a short distance once a month, so a new oil film covers all moving parts and surfaces of components. Also, charge the battery if necessary.

AFTER STORAGE ★ If the machine is stored without carrying out the monthly rust treatment, have maintenance performed by your distributor.

When using the machine after a long period of inactivity, proceed as follows: 1. Remove the seals from the exhaust pipe and fuel tank.

2. Check all fluid levels; engine oil, coolant, fuel, hydraulic system oil.

3. Make sure that the battery charge is sufficient and install the battery.

4. Disconnect the engine stop solenoid. Turn the ignition key directly to the start position and keep it there until the engine oil pressure warning light goes out. This operation serves to start the circulation of lubricating oil and carry out a first lubrication cycle.

WB150AWS-2N

3-65

MAINTENANCE 5. Reconnect the stop solenoid valve and start the engine.

Let the engine run at accelerated speed, 1200 rpm, for about 15 minutes.

6. While the engine is warming up, check the tire pressure and remove the protection grease from the hydraulic cylinder rods.

7. Before moving the machine, make sure that the instruments, lights, direction indicators, and brake stop light work properly.

8. Warm up the hydraulic cylinders, by slowly moving all the work equipment as soon as possible.

9. Move at low speed and brake a few times in order to increase oil viscosity and allow the braking surfaces to seat.

3-66

WB150AWS-2N

4SPECIFICATIONS

WB150AWS-2N

4-1

SPECIFICATIONS

SPECIFICATIONS DIMENSIONS MACHINE

Unit: mm Pos.

A B C D

WB150AWS-2N Standard

WB150AWS-2N Telescopic Arm

2175

2175

2150

2150

2930

2835

7255

7160

E

3650 U 3700 S

3720 U 3770 S

F

2875 U 2925 S

2875 U 2925 S

2420

2420

3780

3780

G H J K

U With standard tires -16.9/24 PR12 149AB S With optional tires -16.9/28 PR12 152AB OFFSET BOOM - - - - - - - - - - - - - - - - - - - - - - - - -

4-2

WB150AWS-2N

SPECIFICATIONS LOADER, BACKHOE - STANDARD ARM

Unit : mm

b c d e f g h

Max Height .......................................

4220

Hinge Pin Height ..............................

3400

Dump Height ....................................

2730

Dump Angle......................................

45°

Dump Reach ....................................

610

Rollback Angle .................................

45°

Loader Digging Depth ......................

90

i Transport Length .............................. j Bucket Reach (Transport) ................

7255

WB150AWS-2N

1) 1!

1@ 1# 1$ 1% 1^

Wheel Base ......................................

2175

Swing Center Distance .....................

1175

Reach at Max Height ........................

3100

Max Digging Height ..........................

5500

Max Dump Height.............................

4060

Digging Depth - SAE ........................

4490

Max Reach from Swing Center.........

5800

1& Digging Reach ..................................

2900

2150

4-3

SPECIFICATIONS LOADER, BACKHOE - TELESCOPIC ARM

b c d e f g h i j 1) 1!

4-4

Max Height .......................................

4220

Hinge Pin Height ..............................

3400

Dump Height ....................................

2730

Dump Angle......................................

45°

Dump Reach ....................................

610

Rollback Angle .................................

45°

Loader Digging Depth ......................

90

Transport Length ..............................

7255

Bucket Reach (Transport) ................

2150

Wheel Base ......................................

2175

Swing Center Distance .....................

1175

1@ 1# 1$ 1% 1^ 1& 1* 1( 2) 2!

2@

Reach at Max Height - Retracted .....

Unit : mm 3100

Reach at Max Height - Extended......

3810

Max Digging Height - Retracted .......

5500

Max Digging Height - Extended........

5940

Max Dump Height - Retracted ..........

4060

Max Dump Height - Extended ..........

4510

Max Digging Depth - Retracted ........

4210

Max Digging Depth - Extended.........

5325

Swing Center Reach - Retracted......

5800

Swing Center Reach - Extended ......

6580

Digging Reach ..................................

2900

WB150AWS-2N

SPECIFICATIONS Unit: As marked ITEM

UNIT Minimum

Operating weight Loader Bucket capacity

8100

8000

9500

8900

1.1

1.1

0.20

0.20

S4D106-1FH

S4D106-2SFA

m³ Backhoe Type

Electrical system

WB150AWS-2N A90009 and UP

kg Maximum

Diesel engine

WB150AWS-2N A90002 to A90008

Max power

kW

72 @ 1200 rpm

72 @ 1200 rpm

Max torque

N•m

375 @ 1500 ±100 rpm

375 @ 1600 ±100 rpm

Alternator

V

12

12

Output

A

80

80

Negative

Negative

Ground Battery

Ah @ V

155 @ 12

160 @ 12

Starter

kW

3

3

Forward 1st

6.5

6.5

Forward 2nd

12

12

Forward 3rd

23

23

40

40

Reverse 1st

6.5

6.5

Reverse 2nd

12

12

Reverse 3rd

23

23

Reverse 4th

40

40

2.2

2.2

2.2

2.2

16.9/24 PR12 149AB

3.2

3.2

16.9/28 PR12 152AB

3.2

3.2

Forward 4th Travel speeds

km/h

16.9/24 PR12 149AB Front tire pressure 16.9/28 PR12 152AB kg/cm² Rear tire pressure

WB150AWS-2N

4-5

SPECIFICATIONS LIFTING CAPACITIES WB150AWS-2N STANDARD ARM Unit: kg

4-6

WB150AWS-2N

SPECIFICATIONS WB150AWS-2N OFFSET STANDARD ARM Unit: kg

WB150AWS-2N

4-7

SPECIFICATIONS WB150AWS-2N TELESCOPIC ARM Unit: kg

4-8

WB150AWS-2N

SPECIFICATIONS WB150AWS-2N OFFSET TELESCOPIC ARM Unit: kg

WB150AWS-2N

4-9

SPECIFICATIONS

4-10

WB150AWS-2N

5OPTIONAL ATTACHMENTS

WB150AWS-2N

5-1

OPTIONAL ATTACHMENTS

AUTHORIZED OPTIONAL EQUIPMENT Komatsu machines can be supplied with optional equipment in addition to the standard equipment. If optional equipment is installed and used, read and study all operations and safety information instructions relating to the optional equipment you will be using. Failure to do so may result in damage to the equipment or injury to the operator. Komatsu cannot be held liable for damage, accident or reduction of machinery performance due to the application and use of unauthorized equipment. Always use authorized equipment.

BASIC PRECAUTIONS When installing or using optional equipment, always contact your distributor first. Be sure the personnel installing or using the optional equipment are trained and authorized to do so. The installation of optional accessories and equipment other than those authorized by Komatsu shortens the life of the machine and may also cause problems concerning safety. It is advisable to contact your distributor before installing any accessory not indicated in this operation and maintenance manual. In case of failure to comply with this rule, Komatsu declines any responsibility for accidents or damage. Listed are some basic safety precautions that must be observed when installing or using optional equipment.

Install or remove optional equipment on a firm level surface.

Be sure the equipment you are installing is in good operating condition. When operations are performed using two or more personnel, agree to a set communication signals in advance and stick to them. Always use an overhead crane when lifting equipment weighing more than 25 kg. Be aware, the center of gravity on your machine will change when optional equipment is installed. Make sure your machine is rated for the optional equipment being installed. When using optional equipment be sure all non authorized personnel are at least 12 m away from your work location. Always support any heavy part before removing it. When heavy parts are lifted, be always careful to the position of the center of gravity of the object being handled. It is very dangerous to carry out any operation with a suspended load; always position the load on a support and make sure that it is in a safe position. When installing or removing any equipment, make sure that it is stable and cannot fall down. Never stand under loads lifted by a crane. Take care to choose a safe position, where you do not run any risk in case the load should fall down.

Remark Specialized personnel is required to operate cranes. Do not allow non specialized personnel to use cranes. For further details regarding installation and removal operations, contact your distributor.

5-2

WB150AWS-2N

OPTIONAL ATTACHMENTS OPTIONAL EQUIPMENT MEASUREMENTS ★ Specific weight of the material handled = 1.8 tons/m³ FRONT END LOADER Max Dimensions

Max Weight

Max Operating Pressure

Max Flow

Height

Max SAE Capacity

Width

Measurement

kg

mm

mm

m³

kg/cm²

l/min

Front bucket

450

2420

940

1.15

---

---

Multi Purpose bucket

750

2420

1015

1.04

204

75

Lifting forks on MP bucket

190

●

●

❑

---

---

Max Operating Pressure

Max Flow

Equipment

BACKHOE UNIT

Equipment

Max Weigh t

Width

Height

Max SAE Capacity

kg

mm

mm

m³

kg/cm²

l/min

305 457 610 762 915

-----------

0.076 0.12 0.18 0.24 0.29

-----------

-----------

Measurement Backhoe bucket Opt Opt Std Opt Opt

Max Dimensions

Ditch cleaning bucket

220

1600

---

0.250

---

---

Trapezoidal bucket

190

2100

900

0.300

---

---

Hydraulic hammer

400

---

---

---

163

80

Drill

360

800✦

2000▲

---

200

120

Clamshell bucket

350

650

1800

0.200

200

120

●

Fork length 1140 mm

❑

Maximum capacity 2000 kg

✦

Measurement referenced to the tool diameter

▲ Measurement referenced to the tool length

WB150AWS-2N

5-3

OPTIONAL ATTACHMENTS

MULTI PURPOSE BUCKET BUCKET OPERATION The MP bucket can be used for several applications. It eliminates the need for specific equipment. It offers the option of a load and scoop bucket as well as a dozer blade for grading and trench filling purposes. The bucket is opened and closed using two hydraulic cylinders b.

A set of optional lifting forks c can be installed for material handling purposes.

DESCRIPTION 1. The bucket jaws e can be opened to unload materials or used as a dozer blade for filling trenches. The MP bucket can be equipped with a tooth protection casing d.

2. By pressing the buttons f and g the bucket jaws can be controlled.

BUCKET USES The bucket can be used for the following applications:

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•

Loading heaped material. Unloading on high surfaces by opening the bucket instead of rolling it forward.

•

Grasping logs or objects.

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Filling trenches and grading.

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OPTIONAL ATTACHMENTS INSTALLATION

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 signals to be used during operations. Do not use your fingers to center the holes, since they may be injured or even cut.

To install the MP bucket it is necessary to engage the mechanical constraints of the loader as described and to carry out the hydraulic connections using the pipes provided.

After coupling the bucket and the loader mechanically, stop the engine, remove the ignition key and move the hydraulic controls more than once in all directions, in order to release the residual pressure that may be present in the circuits; apply the parking brake. When connecting the pipes, take care to prevent any impurities from getting into them.

Proceed as follows: 1. Loosen the protection plugs and remove them from the rigid pipes provided on the machine.

2. Loosen and remove the protection plugs from the flexible pipes i and j of the bucket.

3. Carry out the connections as indicated.

4. Start the machine, raise the bucket a few centimeters from the ground and open and fold it completely more than once with the buttons positioned on the control lever to check the efficiency and tightness of the system.

Wear thick gloves and safety goggles during this check. To check the system for leaks, use a piece of cardboard or a wooden board.

5. Lower the bucket to the ground. Stop the machine. Lubricate the joints, see MULTIPURPOSE BUCKET AND PALLET FORKS on page 3-10. Check the hydraulic oil level, see HYDRAULIC SYSTEM OIL LEVEL on page 334.

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OPTIONAL ATTACHMENTS 6. The bucket is also equipped with an indicator 1) to show the position of the upper part of the bucket.

Before starting work, make sure that the bucket position indicator is correctly set.

MP BUCKET USE The MP bucket can be used for the following applications: 1. Loading, see OPERATING THE LOADER on page 2-96.

2. Unloading on high surfaces by opening the bucket instead of overturning, vertical unloading.

3. Handling of logs, branches, etc. with the pliers function, opening and closing, by using the teeth provided on the mobile jaw e to grasp them.

4. Dozing and levelling, with open bucket.

To doze the ground, open the bucket and move the machine forward working with the fixed part of the bucket. To level the ground, open the bucket and move the machine rearward working with the mobile part of the bucket.

5. The operator can check the opening of the bucket in any condition, by means of the indicator 1).

MAINTENANCE The MP bucket requires maintenance operations in addition to those required for the standard bucket, see MULTIPURPOSE BUCKET AND PALLET FORKS on page 3-10.

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OPTIONAL ATTACHMENTS

PALLET FORK KIT

Before lifting the load, make sure that the position of its center G complies with the distances indicated. Furthermore, the load must always be centered with respect to the forks. Noncompliance with these rules may cause serious damage and even death. Before handling any load, verify the capacity of the forks. The allowed load is generally stamped on the forks.

DESCRIPTION They are mounted to the MP bucket. When not used they are to be overturned towards the back of the machine and secured with the safety pins provided.

The pallet forks b make it possible to use the machine as a normal lift truck and the controls for the lifting and oscillation are the same used to control the standard bucket, see OPERATING THE LOADER on page 2-96.

The distance between the pallet forks can be varied to adapt them to the load to be handled; to do this, make them slide on the coupling bar c and fit between the bucket teeth.

SAFETY DEVICES For this application two safety pins d are provided that keep the forks in the overturned when travelling on roads.

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 therefore it is necessary to be very careful when manoeuvring the machine, especially in reduced spaces. After forking the material, before suspending the load, move the forks in such a way as to lift their prongs and therefore prevent the load from slipping.

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OPTIONAL ATTACHMENTS

When the forks are overturned for use or storage, be careful of the grasp points, since hands and feet may be injured and even cut. It is advisable that this operation be carried out by two persons. Use the lifting, oscillation and shifting controls slowly and smoothly, in order to avoid vibrations that may cause the load to move. Maintain the greatest possible distance between the forks. The forks must always rest on the blade and be positioned between two teeth, in order to avoid any sideward slipping.

PREPARING FORKS FOR USE 1. Turn the forks over towards the front part of the machine.

Raise the bucket and operate the lever in such a way as to swing it forward until the forks are released from the teeth.

2. Move the forks b sidewards to widen or narrow the distance between them according to the width of the load to be handled. Fold the bucket and maneuver the boom until the forks are in horizontal position.

3. Lubricate the rotation pins, see MULTIPURPOSE BUCKET AND PALLET FORKS on page 3-10.

ROTATING FORKS FOR ROAD TRAVEL 1. Remove the safety pins e and the pins d.

2. Make the forks slide towards the center of the bucket, overturn them and insert them in the supports f. Install the pins d and the safety pins e.

3. Make sure that when the forks are overturned in rest position that they are firmly secured inside their respective supports f. If any slack should be observed between the forks and the safety pin d, immediately carry out the necessary adjustment.

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OPTIONAL ATTACHMENTS The correct slack adjusting procedure is as follows: 1. Release the stop nut 1) and loosen the adjusting screw 1! until all slack is eliminated between the fork and safety pin d.

2. After the adjustment, tighten the stop nut 1) thoroughly. If the adjusting screw 1! should be excessively worn, do not hesitate to replace it.

The check and adjustment of the forks must be carried out on both sides, with the forks at rest. Do not hesitate to adjust the forks as soon as the presence of a slack is noticed. Non-compliance with these instructions may lead to dangerous situations for the operator and cause serious damage to the machine. Before carrying out any movement with the machine, make sure that the safety pins e are correctly inserted.

FORK REMOVAL

When removing the forks, the supports and the bar, be very careful, in order not to cut or crush your hands or feet.

1. Maneuver the boom and swing the bucket, resting the forks on the ground in horizontal position b. Remove the safety pins g and the pins h.

2. If also the supports i must be removed loosen and remove the screws j that hold the slide bar c. Hold one of the supports i and withdraw the slide bar; repeat the same operation for the other support.

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OPTIONAL ATTACHMENTS FORK INSTALLATION To install the pallet forks, repeat the procedure described for the removal in the reverse order, taking the same precautions.

MAINTENANCE No specific maintenance operation is required for this device, excepting the occasional greasing of the slide bar and of the fork pin, see MULTIPURPOSE BUCKET AND PALLET FORKS on page 3-10.

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OPTIONAL ATTACHMENTS

OPTIONAL FRONT EQUIPMENT

When removing or installing the optional front mounted equipment, always wear eye and hand protection. Before carrying our removal or installation relieve all hydraulic pressure first. The machine must be parked on flat ground, with the front and rear equipment resting on the ground. For installation, follow the to be installed equipment instructions and requirements. The change of the equipment must be carried out by two operators, who must decide together the words and signals to be used during operations. Do not use your fingers to center the holes, since they may be injured or even cut. Release the residual pressure that may be present in the pipes completely. Before carrying out any operation on the hydraulic circuit, eliminate the residual pressure from the equipment circuits by moving the controls more than once and from the tank by slowly loosening the filler cap. Immediately clean any area dirty with oil.

A 75 l/min flow is available at each side the boom near the front mount position.

1. Use the left button c on the loader control lever b to supply oil to the left boom line.

2. Use the right button d on the loader control lever b to supply oil to the right boom line.

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OPTIONAL ATTACHMENTS

BACKHOE TELESCOPIC ARM The option of extending the backhoe arm makes it possible to perform operations outside of the normal backhoe radius. This would be for grading, ditch cleaning and using optional attachments.

DESCRIPTION AND CONTROL This structure is designed with an external hollow arm b within the inner arm c supporting the equipment slides on a V shaped series of guides. This arm is extended or retracted hydraulically.

The system controlling the telescopic arm movement is controlled by a pedal d positioned in the operators compartment. When the pedal is rocked forward, the arm is extended, when the pedal is rocked backward the arm is retracted.

Remark When the arm is extended, the breakout force of the backhoe is reduced when lifting loads.

The movement of the telescopic arm is achieved by means of the push buttons d and e positioned on the right joystick lever. The movements of the main equipment remain unchanged. The movements of the telescopic arm are controlled as follows: 1. The retraction of the arm is obtained by pressing the push button d, when the button is released, the arm stops.

2. The extension of the arm is obtained by pressing the push button d when the button is released, the arm stops.

When the lock out switch f is engaged, all the movements of the boom, the arm and the equipment are inhibited.

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OPTIONAL ATTACHMENTS SAFETY LOCKS When traveling or operating the front end loader, the safety pin g must be inserted into the telescopic arm and pinned in place A with the kwic pin h.

When using a hammer, compactor, or similar attachments contact your distributor prior to using any attachment with the telescopic arm.

To install the safety lock, retract the arm fully, remove the pin and clip from its holding place and insert it into the holes cut in the arm boss.

When the backhoe is in use, and the telescoping arm is needed, remove the pin g and insert it into the holding place B for the pin Remark Always keep the safety pin with the machine. Never use a substitute or damaged pin. If the pin is missing or damaged, replace it immediately.

MAINTENANCE The telescopic arm requires two maintenance procedures: 1. Lubrication of the joints and fittings, see TELESCOPIC ARM on page 3-11.

2. Adjustment of slide guide j are done occasionally, when impact or vibrations are noticed during work

When leaving the operators compartment to adjust the guides, remove the ignition key and tag the steering wheel.

Adjust the screws and guides one by one. Do not place tools in the space between the safety locks and arm.

GUIDE SLACK ADJUSTMENT 1. Position the machine on a flat firm surface and lower both outriggers.

2. Raise the boom, completely fold the bucket and completely extend the telescopic arm i. Fold the arm until slide guides j are perpendicular to the ground and positioned so that the extendable part is completely free and does not strain the guides.

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OPTIONAL ATTACHMENTS 3. Stop the engine.

4. Check the side which have the guide adjusting dowels 1) protruding the most. Only make adjustments on this side.

Remark If adjusting dowels 1) protrude the same amount on both sides, the next step adjustment can be done on either side.

5. Loosen the four lock nuts 1! and thoroughly tighten adjusting dowels 1), until slack is completely eliminated.

6. Starting from the central position, loosen the adjusting dowels 1) 270° (3 to 4 turns) and lock them with lock nuts 1!.

7. Start the machine, extend and retract the telescopic arm several times to make sure it slides correctly.

8. Lubricate all lubrication points on the telescopic arm.

9. Extend and retract the arm one more time to spread the lubricant on to the slides.

Remark The wear limit allowed for the shoes is represented by the minimum engagement of the adjusting dowels 1) in the lock nuts. The shoes must be replaced when the heads of the dowels are recessed 5 mm inside lock nuts 1!. Do not completely remove all slack, to prevent the guides from seizing.

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OPTIONAL ATTACHMENTS

DEMOLITION HAMMER The machine can be fitted for the application of a demolition hammer on the backhoe unit. This hammer is used for breaking up concrete, asphalt or rocks. The geometry of the tool must be defined according to the nature of the materials to be broken and the type of work to be carried out.

DESCRIPTION AND CONTROL The operation of the hammer is obtained by means of an additional pedal b positioned on the left side of the backhoe control levers.

The hammer is operated by pressing the pedal b. When the pedal is rocked forward, the hammer is activated, when the pedal is rocked backward or released, the hammer is deactivated.

The hammer is operated means of the foot operated pedal c positioned on the cab floor.

The hammer is operated by pressing the foot operated pedal c, pressurized oil is conveyed to the circuit; when the foot pedal is released, oil flow is cut off and the hammer stops.

When the lock out switch d is engaged, all the movements of the boom, the arm and the equipment are inhibited.

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OPTIONAL ATTACHMENTS The arrangement includes the fixed connection of the hydraulic delivery line e and return line f with the hammer g.

RULES FOR HAMMER USAGE

When using the hammer attachment, always wear eye and hearing protection. Never allow anyone to stand near you while using the hammer.

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.

The hammer is used to break floors, cement structures, walls, small rocky surfaces, excavations with open section, asphalt, etc.

With the application of special tools it can also be used as asphalt cutter or compactor.

FOR CORRECT USAGE, IT IS NECESSARY TO 1. Make sure the position of the hammer is correct with respect to the material to be broken. Be sure it is as perpendicular as possible and the arm thrust is sufficient, so that the power of the hammer can be exploited.

2. Keep constant downward pressure on the hammer tool as it penetrates into the material to be broken. This means raising the wheels about 5 cm off the ground. Be careful not to swing or move the machine when performing this operation.

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OPTIONAL ATTACHMENTS 3. When working on very hard materials, it is important not to keep hitting the same point for more than 30 seconds. Hit the same point for a few seconds and then change position very frequently, in order to facilitate the breaking process.

Remark Remember the power in the backhoe unit is the breakout feature when using this tool. Do not use the backhoe unit to reposition or swing the machine to the left or right. Doing so will damage the swing cylinders or possibly tip the machine over.

4. To facilitate the sliding of the tool on its seat, check the thrust direction and always correct the hitting position of the hammer by using the bucket and arm control.

Remark Do not use the demolition hammer with the bucket cylinder at the end of its stroke, always leave a minimum space of 5 cm.

5. Always be sure the arm at its optimal position to avoid harmful or useless strokes.

ALWAYS AVOID THE FOLLOWING USES 1. Gathering or moving materials with the demolition hammer.

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OPTIONAL ATTACHMENTS 2. Rotating the boom while using the hammer Remark Remember the power in the backhoe unit is the breakout feature when using this tool. Do not use the backhoe unit to reposition or swing the machine to the left or right. Doing so will damage the swing cylinders or possibly tip the machine over.

3. Moving the tool back and forth while breaking the material or using the tool as a pry bar between the broken material.

4. Working with the hammer in a horizontal position or even with the greater inclination of the machine.

5. Striking the ground with the hammer bit.

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OPTIONAL ATTACHMENTS 6. Lifting the machine with the demolition hammer 7. Lifting the machine by levering on the hammer bit with the bucket cylinder extended to the end of its stroke.

INSTALLATION AND REMOVAL

When removing or installing the hammer, always wear eye and hand protection. Before carrying our removal or installation relieve all hydraulic pressure first. The machine must be parked on flat ground, with the front equipment resting on the ground. For the installation, the hammer must be positioned horizontally, with the end directed towards the machine. The change of the equipment must be carried out by two operators, who must decide together the words and signals to be used during operations. Do not use your fingers to center the holes, since they may be injured or even cut. Release the residual pressure that may be present in the pipes completely. Before carrying out any operation on the hydraulic circuit, eliminate the residual pressure from the equipment circuits by moving the controls more than once and from the tank by slowly loosening the filler cap. Immediately clean any area dirty with oil.

INSTALLATION For the installation of the demolition hammer it is necessary to connect the mechanical constraints of the backhoe bucket, see CHANGING THE BACKHOE BUCKET on page 2-101.

To carry out hydraulic connections, proceed as follows: 1. Stop the engine and neutralize all the hydraulic controls to relieve all pressure in the system.

2. Press the hammer control pedal to release the pressure in the hydraulic piping for the hammer.

For the installation of the hammer it is necessary to connect the mechanical constraints of the backhoe bucket and to carry out the hydraulic connections using the pipes provided. After connecting the mechanical constraints, carry out the hydraulic connections by proceeding as follows: 3. 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.

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OPTIONAL ATTACHMENTS 4. To release the residual pressure from the machine circuits it is necessary to supply power to the electric circuit, by turning the ignition key to run.

5. Release the backhoe locking device and operate the controls. After releasing the residual pressure from the circuits, turn the ignition key off.

6. Remove the plugs from the hydraulic piping and hoses.

7. Connect the right coupler and then the left coupler. Make sure the connections all match.

When connecting the pipes, be careful not to get impurities between the couplers when installing them.

8. Once connected and tight, start the engine and raise the hammer positioning it vertically.

9. Stop the engine and lubricate all points on the hammer.

Before starting work operations, check for any leaks.

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OPTIONAL ATTACHMENTS REMOVAL To remove the hammer, proceed as follows: 1. Stop the engine and neutralize all the hydraulic controls to relieve all pressure on the system.

2. Operate the hammer controls to release the pressure present in the hammer hydraulic system.

3. Disconnect the hammer delivery and return lines capping them immediately. Disconnect hammer from the constraints.

4. Operate the controls and check for leaks around the caps.

Make sure that the plugs are properly tightened and that there are no leakages; if the circuit is inadvertently pressurized, small leakages can be turned into thin jets that may perforate the skin or injure the eyes. Always wear thick gloves and safety goggles to carry out this check. To check the system for leaks, use a piece of cardboard or a wooden board.

HAMMER USE

If the machine is provided with telescopic arm, it must be kept retracted.

MAINTENANCE The hydraulic system does not require any maintenance operation and inspection other than those prescribed for the machine.

For the maintenance operations required by the hammer, see the specific operation manual.

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OPTIONAL ATTACHMENTS

UNIDIRECTIONAL OIL FLOW EQUIPMENT STANDARD BACKHOE CONTROLS

Some equipment that can be installed instead of the standard bucket make the machine unsuitable for travelling on roads.

Before travelling on roads, always make sure that the machine is suitable for travel with the equipment with which it is provided. The installation and removal of the equipment that is not suitable for travel on roads must be carried out at the work site or in any case in delimited spaces with no traffic.

DESCRIPTION AND CONTROL The machine can be equipped with an independent hydraulic circuit to be used for the operation of optional equipment that may be installed on the backhoe instead of the standard bucket.

The circuit is piloted by an additional hydraulic distributor that is operated by means of a pedal b installed on the left side of the backhoe control lever unit.

The additional circuit is operated as follows: 1. When the pedal b is pressed with the toe, oil is delivered to the right side of the circuit and discharged from the left side of the same.

2. When the pedal b is pressed with the heel, oil is delivered to the left side of the circuit and discharged from the right side of the same.

The movements obtained with the backhoe levers remain unchanged, see BACKHOE CONTROLS - STANDARD on page 244. Except for the bucket control, which is used for the positioning of the optional equipment. This configuration includes also the fixed installation of the delivery and discharge pipes that convey discharge the oil necessary for the operation of the equipment and reach the proximity of the equipment connection.

INSTALLING AND CONNECTING THE EQUIPMENT The equipment must be installed following the procedure indicated, see BUCKET POSITIONS on page 2-99. 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 residual pressure from the machine circuits.

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OPTIONAL ATTACHMENTS

During the successive steps, take care to prevent any impurities from getting into the circuit. Wear thick gloves and safety goggles during this check. To check the system for leaks, use a piece of cardboard or a wooden board.

2. Remove the plugs of the two pipes and of the installed the equipment. Connect the delivery and return pipes.

3. Start the machine, carry out several maneuvers with the pedal b used to control the equipment, in order to verify the tightness of the circuits.

4. Stop the machine and if necessary fasten the longer pipes in order to avoid vibrations and therefore critical conditions for the coupling connections.

MAINTENANCE The hydraulic system does not require any maintenance operation and inspection other than those prescribed for the machine.

For the maintenance operations required by the equipment, see the specific operation manuals.

PPC SYSTEM

Some equipment that can be installed instead of the standard bucket make the machine unsuitable for travelling on roads.

Before travelling on roads, always make sure that the machine is suitable for travel with the equipment with which it is provided. The installation and removal of the equipment that is not suitable for travel on roads must be carried out at the work site or in any case in delimited spaces with no traffic.

DESCRIPTION AND CONTROL The machine can be equipped with an independent hydraulic circuit to be used for the operation of optional equipment that may be installed on the backhoe instead of the standard bucket. The additional circuit is operated with the push buttons c and d positioned on the left joystick. The movements of the main equipment remain unchanged. The additional circuit is operated as follows: 1. When the push button c is pressed, oil is delivered to the right side of the circuit and discharged from the left side.

2. When the push button d is pressed, oil is delivered to the left side of the circuit and discharged from the right side.

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OPTIONAL ATTACHMENTS INSTALLING AND CONNECTING THE EQUIPMENT All the movements of the boom, arm and equipment are inhibited when the lock out switch is engaged. The equipment must be installed by connecting the delivery and return pipes as follows: 1. After connecting the equipment, stop the engine and shift the hydraulic controls in all directions, in order to release the residual pressure from the machine circuits.

To release the residual pressure from the machine circuits, it is necessary to supply power to the electric circuit, turn the ignition key to the run position.

Release the backhoe lock out switch and operate the controls.

After releasing the residual pressure completely from the circuits, turn the ignition key to the off position.

During the successive steps, take care to prevent any impurities from getting into the circuit.

2. Remove the plugs of the two pipes and of the installed equipment. Connect the delivery and return pipes.

3. Start the machine, carry out several maneuvers with the buttons c and d used to control the equipment, in order to verify the tightness of the circuits.

Always wear thick gloves and safety goggles during this check. To check the system for leaks, use a piece of cardboard or a wooden board.

4. Stop the machine and if necessary fasten the longer pipes in order to avoid vibrations and therefore critical conditions for the coupling connections.

The hydraulic system does not require any maintenance operation and inspection other than those prescribed for the machine.

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OPTIONAL ATTACHMENTS

OFFSET BOOM

When it is necessary to move the machine or travel on roads, the offset device must be positioned centrally with respect to the boom axis. To carry out digging operations on vertical walls, the fulcrum pin b of the revolving support c must be perfectly vertical; be very careful to the position of this component when digging near walls and posts, wells and underground lines. When digging near walls, take care not to weaken foundations and cause collapses. When working beyond the outline of the machine, make sure that the ground on which the stabilizers and wheels rest is solid and the area is sufficiently far from ridges, banks, coasts: remember that in these conditions the specific pressure on the ground always increases. Reduce the loads and work at low speed, in order to ensure the stability of the machine.

DESCRIPTION AND CONTROL The offset device is an integral part of the boom d and makes it possible to dig beyond the outline of the machine. If the offset device is in neutral position, the boom can be used as a normal boom; if it is necessary to dig beyond the machines outline, it is necessary to shift the backhoe and operate the device in order to restore the parallelism between the arm e and the machine axis.

STANDARD CONTROLS The operation of the cylinder f that causes the rotation of the support c to which the arm e is mechanically constrained is obtained by means of an additional distributor controlled through a pedal g installed on the left side of the backhoe control lever unit.

The movements of the levers remain unchanged.

The movement of the arm is controlled as follows: 1. When pedal G is pressed rearward with your heel, the arm swings to the left. When the pedal is released the arm stops.

2. When pedal G is pressed forward with your toe, the arm swings to the right. When the pedal is released the arm stops.

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OPTIONAL ATTACHMENTS PPC SYSTEM The movement of the equipment with offset device is obtained by the push buttons h and i positioned on the left joystick lever.

The movements of the main equipment remain unchanged.

The movements of the arm are controlled as follows: 1. When the push button h is pressed, the arm swings to the left and when the button is released the arm stops.

2. When the push button i is pressed, the arm swings to the right and when the button is released the arm stops.

When the lock out switch is engaged, all the movements of the boom, the arm and the equipment are inhibited.

The offset device does not require any special maintenance operation, except for greasing.

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OPTIONAL ATTACHMENTS

CLAMSHELL BUCKET The machine can be arranged for the installation of a clamshell type bucket on the backhoe instead of the standard digging bucket. The installation of the clamshell bucket allows the option of picking up material from a single point rather than scooping it with the digging bucket.

If the machine will be equipped with a clamshell bucket, it is advised not to travel on roads due to size and fact the clamshell is suspended from the arm and will swing when traveling. All work with the clamshell bucket must start and end at the work site.

DESCRIPTION AND CONTROL STANDARD CONTROLS For the swing movement of the clamshell bucket an independent hydraulic circuit controlled by an additional distributor is provided, while the opening and closing operation is controlled by the standard backhoe digging bucket circuit. The other movements for the backhoe remain unchanged, see USING THE BACKHOE on page 2-98.

•

The clockwise rotation of the bucket is obtained by pressing the foot pedal, rolling it forward.

•

The counterclockwise rotation of the bucket is obtained by pressing the foot pedal, rolling it backward.

•

To open the clamshell, move the right joy stick to the right, and to close the clamshell, move the right joy stick to the left

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OPTIONAL ATTACHMENTS PPC SYSTEM The swinging movements of the clamshell bucket are operated through the push buttons c and d positioned on the left joystick lever.

The movements of the main equipment (boom, arm and boom swing) remain unchanged.

The circuit used for opening and folding the standard bucket is used also for opening and closing the clamshell bucket, excluding the control cylinder.

The swing movements of the bucket are controlled as follows: 1. When the lever push button c is pressed, the bucket swings clockwise.

2. When the lever push button d is pressed, the bucket swings counterclockwise.

All the movements of the boom, the arm and the equipment are inhibited when the lock out switch is applied.

The machine must be parked on level flat ground, with the front equipment resting on the ground. 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 persons, who must decide together the words and signals to be used during operations. Do not use your fingers to center the holes, since they may be injured or even cut. Release the residual pressure that may be present in the lines completely.

To install the revolving clamshell bucket, proceed as follows: 1. Remove the standard bucket from the backhoe.

2. Retract the bucket cylinder rod completely.

3. Connect the clamshell bucket to the arm.

4. Stop the machine and move the controls in all directions to release the residual pressures.

To release the residual pressure from the machine circuits it is necessary to supply power to the electric circuit, by turning the ignition key to run position. Release the backhoe lock out switch.

Operate the controls.

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OPTIONAL ATTACHMENTS To release the residual pressure from the machine circuits it is necessary to supply power to the electric circuit, by turning the ignition key to run position. Release the backhoe lock out switch.

Operate the controls.

After releasing the residual pressure from the circuits completely, turn the ignition key to the off position.

INSTALLATION

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; 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 signals to be used during operations.

Do not use your fingers to center the holes, since they may be injured or even cut. Release the residual pressure that may be present in the pipes completely.

To install the clamshell bucket the aid of another person will be required. To perform installation procedures, proceed as follows: 1. Neutralize all hydraulic controls and remove the standard digging bucket, see BUCKET POSITIONS on page 2-99.

2. Retract the bucket cylinder completely.

3. Install the clamshell bucket to the arm.

4. Stop the machine and neutralize all the hydraulic controls.

5. Lock the bucket cylinder rod in place at the end of its stroke.

6. In A disconnect the supply lines c and d that operate the bucket cylinder b. Seal the couplings e.

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OPTIONAL ATTACHMENTS 7. In B disconnect the supply lines c and d that operate the bucket cylinder b. Seal the couplings e.

8. Connect the supply lines from the standard bucket cylinder to the lines controlling the clamshell bucket.

9. Be sure all unused lines are capped and sealed. be careful when installing lines. Be sure dirt or debris does not get trapped in these couplings.

10. Start the machine and raise the clamshell off the ground.

11. Open close and swing the bucket several times.

REMOVAL To remove the clamshell bucket follow the reverse order of installation.

Always wear thick gloves and safety goggles during this check. To check the system for leaks, use a piece of cardboard or a wooden board.

OPERATING THE CLAMSHELL BUCKET Consult the specific operators manual for the clamshell bucket.

MAINTENANCE For the maintenance operations required by the clamshell bucket, see the specific operation manual.

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OPTIONAL ATTACHMENTS

HYDRAULIC JACK HAMMER

The manual hydraulic hammer is very noisy; always wear headphones when using it. The manual hydraulic hammer transmits intense vibrations that may cause physical harm and/or stress to the operator. Be extremely careful especially at the end of work and have short rests when you lose sensibility in the upper limbs.

The machine can be equipped with off machine hydraulics, a hammer or similar approved tool may be used. This option eliminates the need for an independent power source when using some power tools.

DESCRIPTION AND CONTROL The machine is provided, when ordered, with the delivery b and return c couplings for the use of a manual hydraulic hammer.

The connection to the machine is made up of two flexible lines d.

The circuit is separated from the normal circuits by a solenoid valve and activated by a switch e positioned on the dash board.

By pressing the switch once energizes the solenoid and allows the system to operate. If the switch is pressed a second time, the system is disengaged.

When the system is in operation the switch will be illuminated.

For operation of the hammer, see the manual provided with the tool.

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OPTIONAL ATTACHMENTS

Connection and removal of the hammer must be carried out with the machine in the parked position, parking brake set and all safety locks engaged.

CONNECTING THE JACK HAMMER Stop the engine and neutralize all hydraulic controls to relieve any pressure on the system. Turn ignition switch to the IGN position and press the switch e to release any residual pressure from the hammer. Make sure the couplings are clean and free from dirt or debris. Carefully install the couplings. Turn the switch e off and start the engine. Engage the switch e and increase the engine RPM to required setting in the tool operation manual.

DISCONNECTING THE JACK HAMMER Press the button e to disengage the solenoid and shut the hydraulics down. Stop the engine and neutralize all hydraulic controls to relieve any pressure on the system. Turn the ignition switch to the IGN position and press the switch e to release any residual pressure from the hammer. Turn the switch off. Disconnect the tool and cap all openings.

If quick attachments are not provided, place sealing plugs with the relevant gaskets on the couplings of the machine and of the hammer. Make sure that the plugs are properly tightened and that there is no leakages; if the circuit is inadvertently pressurized, small leakages can be turned into thin jets that may perforate the skin or injure the eyes. Always wear thick gloves and safety goggles to carry out this check.

To check the system for leaks, use a piece of cardboard or a wooden board.

USING THE HAMMER For operation of jack hammer, see manual provided with the tool.

If the machine is provided with telescopic arm, it must be kept retracted.

MAINTENANCE The hydraulic system does not require any maintenance other than those prescribed for the machine. For the maintenance operations required for the hammer, see the hammer operation manual.

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OPTIONAL ATTACHMENTS

LOAD STABILIZER SYSTEM (LSS)

Never operate the load stabilizer system while using the backhoe. If the machine is provided with safety valves on the front loader make sure that they are not connected.

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. It also reduces to a minimum the impact forces to which the machine may be subjected.

When the load stabilizer system is in operation, the loader pressure in low position is limited to that supplied by the weight of the arms and the bucket. The bucket weight is hydraulically cushioned when the machine is moving.

To operate the load stabilizer system, press the switch b (LED on) positioned on the side dashboard. When the operation of the system is not required any longer, move the switch back to the neutral position (LED off).

ACCUMULATORS

If it is necessary to repair or change the accumulator of the load stabilizer system, contact your distributor. Failure to comply with this instruction may cause serious injuries and even death.

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OPTIONAL ATTACHMENTS

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Komatsu America Corp.

Data Kom Publications & Training 440 North Fairway Drive Vernon Hills, Il. 60061-8112 U.S.A. Attn: Service Publications Fax No. (847)-970-4186

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