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Komatsu Sk714-5 Skid Steer Loader Operation & Maintenance Manual – PDF Download
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Komatsu Sk714-5 Skid Steer Loader Operation & Maintenance Manual
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Description
Komatsu Sk714-5 Skid Steer Loader Operation & Maintenance Manual
Description:
Komatsu Sk714-5 Skid Steer Loader Operation & Maintenance Manual
• This manual is supplied by Komatsu Utility S.p.A. in order to provide customers with all the necessary information on the machine and the safety regulations related to it, together with the use and maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time.
• The operation manual, together with the spare parts catalogue, is an integral part of the machine and must accompany it, even when it is resold, until its final disposal.
• The manual must be handled with the greatest care and always kept on board the machine, so that it can be consulted at any moment; it must be placed in the appropriate compartment, 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 to Komatsu Utility or to your Komatsu Utility Dealer.
• The illustrations contained in this manual may represent machine configurations that are available on request.Komatsu Utility 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 updated information, contact your Komatsu Utility Dealer.
• Punctual periodic annotations regarding the maintenance operations that have been carried out are important to have a clear prospect of the situation and to know exactly what has been done and what has to be done after the next maintenance interval. Therefore, it is advisable to consult either the hour meter and the maintenance plan frequently.
• Over the years Komatsu Utility Dealers have gathered considerable experience in customer service. If more information is needed, do not hesitate to contact your Komatsu Utility Dealer: 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, Komatsu Utility Dealers also ensure their assistance for the supply of Komatsu Utility 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 Dealer when requiring assistance and ordering spare parts.
Table of Contents:
Komatsu Sk714-5 Skid Steer Loader Operation & Maintenance Manual
1.1 FOREWORD........................................................................................................ 3 1.2 INFORMATION ON SAFETY........................................................................................... 4 1.3 INTRODUCTION.................................................................................................... 6 1.3.1 INTENDED USES............................................................................................. 6 1.3.2 IMPROPER OR UNAUTHORIZED USES............................................................................. 6 1.3.3 MAIN CHARACTERISTICS...................................................................................... 7 1.3.4 RUNNING-IN................................................................................................ 7 1.4 PRODUCT IDENTIFICATION.......................................................................................... 8 1.4.1 MACHINE SERIAL NUMBER..................................................................................... 8 1.4.2 MACHINE IDENTIFICATION PLATE.............................................................................. 8 1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE....................................................... 9 1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....................................................................... 9 1.4.5 CAB SERIAL NUMBER......................................................................................... 10 1.4.6 EXCAVATOR IDENTIFICATION PLATE (if installed)............................................................. 10 1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS....................................................................... 11 TABLE OF CONTENTS................................................................................................... 12 1.1 FOREWORD 1.................................................................................................. 12 1.2 INFORMATION ON SAFETY 2..................................................................................... 12 1.3 INTRODUCTION 4.............................................................................................. 12 1.3.1 INTENDED USES 4....................................................................................... 12 1.3.2 IMPROPER OR UNAUTHORIZED USES 4....................................................................... 12 1.3.3 MAIN CHARACTERISTICS 5................................................................................ 12 1.3.4 RUNNING-IN 5.......................................................................................... 12 1.4 PRODUCT IDENTIFICATION 6.................................................................................... 12 1.4.1 MACHINE SERIAL NUMBER 6............................................................................... 12 1.4.2 MACHINE IDENTIFICATION PLATE 6........................................................................ 12 1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE 7................................................. 12 1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER 7................................................................. 12 1.4.5 CAB SERIAL NUMBER 8................................................................................... 12 1.4.6 EXCAVATOR IDENTIFICATION PLATE (if installed) 8....................................................... 12 1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS 9................................................................. 12 2.1 SAFETY, NOISE AND VIBRATION PLATES 18....................................................................... 12 2.1.1 POSITION OF THE SAFETY PLATES 18...................................................................... 12 2.1.1.1 SAFETY PLATES 18................................................................................ 12 2.1.1.2 SAFETY PLATES FOR MACHINES WITH EXCAVATOR 20.................................................... 12 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS 22................................................................... 12 2.1.3 POSITION OF THE NOISE PLATES 26....................................................................... 12 2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED 26...................................................... 12 2.2 GENERAL PRECAUTIONS 27...................................................................................... 12 2.2.1 GENERAL SAFETY RULES 27............................................................................... 12 2.2.2 SAFETY DEVICES AND GUARDS 27.......................................................................... 12 2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS 27............................................................. 12 2.2.4 UNAUTHORIZED MODIFICATIONS 28......................................................................... 12 2.2.5 LEAVING THE OPERATORS SEAT 28......................................................................... 12 2.2.6 GETTING ON AND OFF THE MACHINE 29..................................................................... 12 2.2.7 CHECKING THE REAR-VIEW MIRRORS (if installed) 29...................................................... 12 2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL 30............................................................... 12 2.2.9 PREVENTING BURNS 30................................................................................... 12 2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER 31.......................................................... 12 2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT 31.................................................... 12 2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT 32.............................................................. 12 2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE 32.......................................................... 12 2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT 32.............................................................. 12 2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 33....................................................... 12 2.3.1 SAFETY ON THE WORK SITE 33............................................................................ 12 2.3.2 FIRE PREVENTION 33.................................................................................... 12 2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB 33..................................................... 12 2.3.4 ROOM VENTILATION 34................................................................................... 12 2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (if installed) 34.............................................. 12 2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES (if i........... 12 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING 35..................................................................... 13 2.4.1 STARTING THE ENGINE 35................................................................................ 13 2.4.2 RULES TO BE FOLLOWED WHEN TRAVELLING ON ROADS 35...................................................... 13 2.4.3 CHECKS FOR TRAVELLING IN REVERSE 36................................................................... 13 2.4.4 MOVING THE MACHINE 37................................................................................. 13 2.4.5 WORKING ON SLOPES 37.................................................................................. 13 2.4.6 PREVENTING ELECTROCUTION 39........................................................................... 13 2.4.7 VISIBILITY 40......................................................................................... 13 2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES 40............................................................ 13 2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT 40..................................................... 13 2.4.10 WORKING ON LOOSE GROUND 40........................................................................... 13 2.4.11 PARKING THE MACHINE 41............................................................................... 13 2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES 42............................................................... 13 2.5.1 LOADING AND UNLOADING THE MACHINE 42.................................................................. 13 2.5.2 THE ROUTE 42.......................................................................................... 13 2.6 BATTERY 43.................................................................................................. 13 2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES 43........................................................... 13 2.6.2 STARTING WITH BOOSTER CABLES 43....................................................................... 13 2.7 PRECAUTIONS FOR EMERGENCY RECOVERY 44....................................................................... 13 2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 46............................................................... 13 2.8.1 WARNING PLATES 46..................................................................................... 13 2.8.2 TOOLS 46.............................................................................................. 13 2.8.3 PERSONNEL 47.......................................................................................... 13 2.8.4 EQUIPMENT 47.......................................................................................... 13 2.8.5 WORKING UNDER THE MACHINE 47.......................................................................... 13 2.8.6 KEEPING THE MACHINE CLEAN 47.......................................................................... 13 2.8.7 USE OF THE ENGINE DURING MAINTENANCE 48............................................................... 13 2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY 48........................................ 13 2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION 48........................ 13 2.8.10 RULES FOR REFUELLING AND ADDING OIL 49............................................................... 13 2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR 49........................................................ 13 2.8.12 USING LAMPS 49....................................................................................... 13 2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR 50............................................. 13 2.8.14 PRECAUTIONS CONCERNING THE STARTER 50................................................................ 13 2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES 51........................................................ 13 2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS 51..................................... 13 2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES 51........................ 13 2.8.18 COOLING FAN AND FAN BELT 52.......................................................................... 13 2.8.19 WASTE MATERIALS 52................................................................................... 13 2.8.20 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES 52.................................................. 13 2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODEGRADABLE OIL TYPE «HEES» 53.................... 13 3.1 SAFETY LOCKS 56............................................................................................. 14 3.1.1 LOADER LOCKS 56....................................................................................... 14 3.1.2 EXCAVATOR LOCKS (if installed) 58..................................................................... 14 3.1.3 ASPHALT CUTTER LOCKS (if installed) 60................................................................ 14 3.2 GENERAL VIEWS 61............................................................................................ 14 3.2.1 FRONT GENERAL VIEW 61................................................................................. 14 3.2.2 REAR GENERAL VIEW 62.................................................................................. 14 3.2.3 CAB INSIDE GENERAL VIEW 63............................................................................ 14 3.3 INSTRUMENTS AND CONTROLS 65................................................................................. 14 3.3.1 INSTRUMENTS 65........................................................................................ 14 3.3.2 WARNING LIGHTS 67..................................................................................... 14 3.3.3 SWITCHES UND PUSH BUTTONS 72.......................................................................... 14 3.3.4 ELECTRICAL ACCESSORIES 77............................................................................. 14 3.3.5 MACHINE CONTROLS 78................................................................................... 14 3.4 FUSES AND RELAYS 96......................................................................................... 14 3.4.1 MACHINE FUNCTION FUSES 96............................................................................. 14 3.4.2 MAIN FUSE 97.......................................................................................... 14 3.4.3 RELAYS 98............................................................................................. 14 3.5 GUARDS AND DRIVER’S SEAT 100................................................................................ 14 3.5.1 ENGINE HOOD 100....................................................................................... 14 3.5.2 REAR PANEL 101........................................................................................ 14 3.5.3 CAB 102............................................................................................... 14 3.5.3.1 RAISING THE CAB 103............................................................................. 14 3.5.4 STANDARD SEAT 105..................................................................................... 14 3.5.5 CUSHIONED SEAT 105.................................................................................... 14 3.5.6 SAFETY BELT 106....................................................................................... 14 3.5.7 EMERGENCY EXIT 106.................................................................................... 14 3.5.8 TECHNICAL DOCUMENTATION CASE 107...................................................................... 14 3.5.9 FIRE EXTINGUISHER 107................................................................................. 14 3.5.10 FIRST AID KIT 107.................................................................................... 14 3.6 USE OF THE MACHINE 109...................................................................................... 14 3.6.1 CHECKS BEFORE STARTING THE ENGINE 109................................................................. 14 3.6.1.1 VISUAL CHECKS 109............................................................................... 14 3.6.1.2 DAILY CHECKS 109................................................................................ 14 3.6.1.3 OPERATIONAL CHECKS 110.......................................................................... 14 3.6.2 STARTING THE ENGINE 111............................................................................... 14 3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES 111.......................................... 14 3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES 112............................................... 14 3.6.3 WARMING THE ENGINE 113................................................................................ 14 3.6.4 HEATING THE HYDRAULIC OIL 113......................................................................... 14 3.6.5 HOW TO MOVE THE MACHINE (ISO PATTERN CONTROL SYSTEM) 113.............................................. 14 3.6.5.1 STEERING (CHANGING DIRECTION) 115............................................................... 14 3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM) 117......................................... 14 3.6.6.1 STEERING (CHANGING DIRECTION) 119............................................................... 14 3.6.7 MOVING ON SLOPES 121.................................................................................. 14 3.6.8 MAXIMUM IMMERSION DEPTH 122........................................................................... 14 3.7 PARKING THE MACHINE 123..................................................................................... 15 3.7.1 PARKING ON LEVEL GROUND 123........................................................................... 15 3.7.2 PARKING ON SLOPES 124................................................................................. 15 3.8 STOPPING THE ENGINE 125..................................................................................... 15 3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES 126.............................................................. 15 3.9.1 LOADING AND UNLOADING THE MACHINE 126................................................................. 15 3.9.2 TRANSPORT 127......................................................................................... 15 3.10 HOW TO LIFT THE MACHINE 128................................................................................ 15 3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 129............................................................. 15 3.11.1 FUEL AND LUBRICANTS 129.............................................................................. 15 3.11.2 COOLANT 129.......................................................................................... 15 3.11.3 BATTERY 130.......................................................................................... 15 3.11.4 OTHER PRECAUTIONS 130................................................................................ 15 3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK 130....................................................... 15 3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 131............................................................. 15 3.13 USING THE WORK EQUIPMENT 132............................................................................... 15 3.13.1 LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE 132................................................ 15 3.13.2 ORGANIZING THE WORK AREA 133......................................................................... 15 3.13.3 LOADING MATERIAL ON HEAPS AND ON LEVEL SURFACES 134.................................................. 15 3.13.4 LOADING MATERIAL ON SLOPES 135....................................................................... 15 3.13.5 DIGGING METHOD 136................................................................................... 15 3.13.6 CHANGING THE BUCKET WITH STANDARD RAPID COUPLING 137................................................. 15 3.13.6.1 RELEASING THE BUCKET 138....................................................................... 15 3.13.6.2 COUPLING THE BUCKET 138........................................................................ 15 3.13.7 CHANGING THE BUCKET WITH OPTIONAL RAPID COUPLING 140................................................. 15 3.13.7.1 RELEASING THE BUCKET 141....................................................................... 15 3.13.7.2 COUPLING THE BUCKET 141........................................................................ 15 3.14 LONG PERIODS OF INACTIVITY 143............................................................................. 15 3.14.1 BEFORE THE PERIOD OF INACTIVITY 143.................................................................. 15 3.14.2 DURING THE PERIOD OF INACTIVITY 144.................................................................. 15 3.14.3 AFTER THE PERIOD OF INACTIVITY 144................................................................... 15 3.15 TROUBLESHOOTING 145........................................................................................ 15 3.15.1 HOW TO REMOVE THE MACHINE 145........................................................................ 15 3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED 145......................................................... 15 3.15.3 IF THE BATTERY IS DEPLETED 146....................................................................... 15 3.15.3.1 STARTING WITH BOOSTER CABLES 147............................................................... 15 3.15.4 OTHER TROUBLES 148................................................................................... 15 3.15.4.1 ELECTRICAL CIRCUIT 148......................................................................... 15 3.15.4.2 HYDRAULIC SYSTEM 149........................................................................... 15 3.15.4.3 ENGINE 150..................................................................................... 15 3.15.4.4 HYDROSTATIC TRANSMISSION 151................................................................... 15 4.1 GUIDE TO MAINTENANCE 154.................................................................................... 16 4.2 MAINTENANCE NOTES 156....................................................................................... 16 4.2.1 NOTES REGARDING THE ENGINE 156........................................................................ 16 4.2.1.1 ENGINE OIL 156.................................................................................. 16 4.2.1.2 COOLANT 156..................................................................................... 16 4.2.1.3 FUEL 157........................................................................................ 16 4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM 157.............................................................. 16 4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM 158............................................................. 16 4.2.4 NOTES REGARDING LUBRICATION 158....................................................................... 16 4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING 159............................................. 16 4.3 FUEL, COOLANT AND LUBRICANTS 160............................................................................ 16 4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES 162.......................................... 16 4.4 DRIVING TORQUES FOR SCREWS AND NUTS 163..................................................................... 16 4.4.1 STANDARD DRIVING TORQUES 163.......................................................................... 16 4.4.2 SPECIFIC DRIVING TORQUES 163.......................................................................... 16 4.5 LUBRICATION 164............................................................................................. 16 4.5.1 LUBRICATION DIAGRAM 164............................................................................... 16 4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 165............................................... 16 4.6.1 CRITICAL PARTS FOR SAFETY 166......................................................................... 16 4.7 MAINTENANCE PLAN 172........................................................................................ 16 4.7.1 WHEN REQUIRED 175..................................................................................... 16 4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE 175.................................... 16 4.7.1.b TYRE ROTATION 176............................................................................... 16 4.7.1.c WASHING THE COOLING CIRCUIT 177................................................................. 16 4.7.1.d DRAINING THE FUEL TANK 178...................................................................... 16 4.7.1.e RELEASING THE PARKING BRAKE 179................................................................. 16 4.7.2 CHECKS BEFORE STARTING 180............................................................................ 16 4.7.2.a VARIOUS CHECKS 180.............................................................................. 16 4.7.2.b CHECKING THE COOLANT LEVEL 180.................................................................. 16 4.7.2.c CHECKING THE FUEL LEVEL 181..................................................................... 16 4.7.2.d CHECKING THE ENGINE OIL LEVEL 182............................................................... 16 4.7.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT 183............................................. 16 4.7.2.f CHECKING THE FUEL FILTER FOR SEDIMENTS AND WATER 184............................................ 16 4.7.2.g CHECKING THE WIRING SYSTEM 184.................................................................. 16 4.7.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION 185................................................. 16 4.7.4 MAINTENANCE EVERY 50 HOURS OF OPERATION 185........................................................... 16 4.7.4.a CHECKING THE TYRE PRESSURE 185.................................................................. 16 4.7.4.b CHECKING THE COOLANT LEVEL IN THE RADIATOR 185.................................................. 16 4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION 186................................................ 16 4.7.6 MAINTENANCE EVERY 250 HOURS OF OPERATION 186.......................................................... 16 4.7.6.a ADJUSTING THE FAN BELT TENSION 186.............................................................. 16 4.7.6.b CHECKING THE BATTERY ELECTROLYTE LEVEL 187...................................................... 16 4.7.6.c CHECKING THE GEARING CHAIN TENSION 188.......................................................... 16 4.7.6.d CLEANING THE OUTSIDE OF THE RADIATORS 189....................................................... 16 4.7.6.e CHECKING THE WHEEL NUT DRIVING TORQUE 190....................................................... 16 4.7.6.f CHECKING THE OIL LEVEL IN THE FINAL TRANSMISSIONS 190........................................... 16 4.7.6.g LUBRICATING THE JOINTS 191...................................................................... 16 4.7.6.h CHANGING THE ENGINE OIL 192..................................................................... 16 4.7.6.j CHANGING THE ENGINE OIL FILTER 193.............................................................. 16 4.7.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines filled with synthetic........... 17 4.7.8 MAINTENANCE EVERY 500 HOURS OF OPERATION 194.......................................................... 17 4.7.8.a CHANGING THE FUEL FILTER 194.................................................................... 17 4.7.8.b CHANGING THE HYDRAULIC OIL DRAIN FILTER 196..................................................... 17 4.7.8.c CHANGING THE FUEL PUMP PRECLEANER 197........................................................... 17 4.7.8.d DRAINING THE HYDRAULIC OIL TANK (Only for machines filled with synthetic biodegradable oi....... 17 4.7.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION 200......................................................... 17 4.7.9.a CHANGING THE OIL IN THE FINAL TRANSMISSION 200.................................................. 17 4.7.9.b CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER 201........................... 17 4.7.9.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE 203........................................... 17 4.7.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION 204........................................................ 17 4.7.10.a CHANGING THE COOLANT 204....................................................................... 17 4.7.10.b CHANGING THE SUCTION FILTER 206................................................................ 17 4.7.10.c CHECKING THE ALTERNATOR AND THE STARTER 207.................................................... 17 5.1 TECHNICAL DATA 210.......................................................................................... 17 5.1.1 STANDARD MACHINE OVERALL DIMENSIONS 210............................................................... 17 5.1.2 MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT 212................................................ 17 5.1.3 TECHNICAL CHARACTERISTICS 214......................................................................... 17 6.1 AUTHORIZED OPTIONAL EQUIPMENT 218........................................................................... 17 6.1.1 PRECAUTIONS REGARDING SAFETY 218...................................................................... 17 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT 219............................................... 17 6.1.3 CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT 220........................................ 17 6.1.4 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION WITH HIGH-FLOW HYDRAULIC S........... 17 6.2 CHANGING THE AUTHORIZED EQUIPMENT 222....................................................................... 17 6.2.1 CONNECTING THE EXCAVATOR 222.......................................................................... 17 6.2.2 CONNECTING THE HYDRAULIC CIRCUIT 223.................................................................. 17 6.2.3 CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK 225.................................. 17 6.2.4 PREPARING THE MACHINE FOR THE USE OF THE EXCAVATOR 226................................................ 17 6.2.5 USING THE MACHINE WITH THE EXCAVATOR 226.............................................................. 17 6.3 PALLET FORKS 227............................................................................................ 17 2.1 SAFETY, NOISE AND VIBRATION PLATES.............................................................................. 20 2.1.1 POSITION OF THE SAFETY PLATES............................................................................. 20 2.1.1.1 SAFETY PLATES....................................................................................... 20 2.1.1.2 SAFETY PLATES FOR MACHINES WITH EXCAVATOR........................................................... 22 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS.......................................................................... 24 2.1.3 POSITION OF THE NOISE PLATES.............................................................................. 28 2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED............................................................. 28 2.2 GENERAL PRECAUTIONS............................................................................................. 29 2.2.1 GENERAL SAFETY RULES...................................................................................... 29 2.2.2 SAFETY DEVICES AND GUARDS................................................................................. 29 2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS.................................................................... 29 2.2.4 UNAUTHORIZED MODIFICATIONS................................................................................ 30 2.2.5 LEAVING THE OPERATORS SEAT................................................................................ 30 2.2.6 GETTING ON AND OFF THE MACHINE............................................................................ 31 2.2.7 CHECKING THE REAR-VIEW MIRRORS (if installed)............................................................. 31 2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL...................................................................... 32 2.2.9 PREVENTING BURNS.......................................................................................... 32 2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER................................................................. 33 2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT........................................................... 33 2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT..................................................................... 34 2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE................................................................. 34 2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT..................................................................... 34 2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE.............................................................. 35 2.3.1 SAFETY ON THE WORK SITE................................................................................... 35 2.3.2 FIRE PREVENTION........................................................................................... 35 2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB............................................................ 35 2.3.4 ROOM VENTILATION.......................................................................................... 36 2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (if installed)..................................................... 36 2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES (if i............... 36 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................................ 37 2.4.1 STARTING THE ENGINE....................................................................................... 37 2.4.2 RULES TO BE FOLLOWED WHEN TRAVELLING ON ROADS............................................................. 37 2.4.3 CHECKS FOR TRAVELLING IN REVERSE.......................................................................... 38 2.4.4 MOVING THE MACHINE........................................................................................ 39 2.4.5 WORKING ON SLOPES......................................................................................... 39 2.4.6 PREVENTING ELECTROCUTION.................................................................................. 41 2.4.7 VISIBILITY................................................................................................ 42 2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES................................................................... 42 2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT............................................................ 42 2.4.10 WORKING ON LOOSE GROUND.................................................................................. 42 2.4.11 PARKING THE MACHINE...................................................................................... 43 2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...................................................................... 44 2.5.1 LOADING AND UNLOADING THE MACHINE......................................................................... 44 2.5.2 THE ROUTE................................................................................................. 44 2.6 BATTERY......................................................................................................... 45 2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES.................................................................. 45 2.6.2 STARTING WITH BOOSTER CABLES.............................................................................. 45 2.7 PRECAUTIONS FOR EMERGENCY RECOVERY.............................................................................. 46 2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...................................................................... 48 2.8.1 WARNING PLATES............................................................................................ 48 2.8.2 TOOLS..................................................................................................... 48 2.8.3 PERSONNEL................................................................................................. 49 2.8.4 EQUIPMENT................................................................................................. 49 2.8.5 WORKING UNDER THE MACHINE................................................................................. 49 2.8.6 KEEPING THE MACHINE CLEAN................................................................................. 49 2.8.7 USE OF THE ENGINE DURING MAINTENANCE...................................................................... 50 2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY............................................... 50 2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION............................... 50 2.8.10 RULES FOR REFUELLING AND ADDING OIL...................................................................... 51 2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR............................................................... 51 2.8.12 USING LAMPS.............................................................................................. 51 2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR.................................................... 52 2.8.14 PRECAUTIONS CONCERNING THE STARTER....................................................................... 52 2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES............................................................... 53 2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS............................................ 53 2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES............................... 53 2.8.18 COOLING FAN AND FAN BELT................................................................................. 54 2.8.19 WASTE MATERIALS.......................................................................................... 54 2.8.20 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES......................................................... 54 2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»........................... 55 3.1 SAFETY LOCKS.................................................................................................... 58 3.1.1 LOADER LOCKS.............................................................................................. 58 3.1.2 EXCAVATOR LOCKS (if installed)............................................................................ 60 3.1.3 ASPHALT CUTTER LOCKS (if installed)....................................................................... 62 3.2 GENERAL VIEWS................................................................................................... 63 3.2.1 FRONT GENERAL VIEW........................................................................................ 63 3.2.2 REAR GENERAL VIEW......................................................................................... 64 3.2.3 CAB INSIDE GENERAL VIEW................................................................................... 65 3.3 INSTRUMENTS AND CONTROLS........................................................................................ 67 3.3.1 INSTRUMENTS............................................................................................... 67 3.3.2 WARNING LIGHTS............................................................................................ 69 3.3.3 SWITCHES UND PUSH BUTTONS................................................................................. 74 3.3.4 ELECTRICAL ACCESSORIES.................................................................................... 79 3.3.5 MACHINE CONTROLS.......................................................................................... 80 3.4 FUSES AND RELAYS................................................................................................ 98 3.4.1 MACHINE FUNCTION FUSES.................................................................................... 98 STANDARD VERSION............................................................................................ 98 VERSION WITH OPTIONALS...................................................................................... 99 3.4.2 MAIN FUSE................................................................................................. 99 3.4.3 RELAYS....................................................................................................100 3.5 GUARDS AND DRIVER’S SEAT........................................................................................102 3.5.1 ENGINE HOOD...............................................................................................102 3.5.2 REAR PANEL................................................................................................103 3.5.3 CAB.......................................................................................................104 3.5.3.1 RAISING THE CAB.....................................................................................105 3.5.4 STANDARD SEAT.............................................................................................107 3.5.5 CUSHIONED SEAT............................................................................................107 3.5.6 SAFETY BELT...............................................................................................108 3.5.7 EMERGENCY EXIT............................................................................................108 3.5.8 TECHNICAL DOCUMENTATION CASE..............................................................................109 3.5.9 FIRE EXTINGUISHER.........................................................................................109 3.5.10 FIRST AID KIT............................................................................................109 3.6 USE OF THE MACHINE..............................................................................................111 3.6.1 CHECKS BEFORE STARTING THE ENGINE.........................................................................111 3.6.1.1 VISUAL CHECKS.......................................................................................111 3.6.1.2 DAILY CHECKS........................................................................................111 3.6.1.3 OPERATIONAL CHECKS..................................................................................112 3.6.2 STARTING THE ENGINE.......................................................................................113 3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES..................................................113 3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES.......................................................114 3.6.3 WARMING THE ENGINE........................................................................................115 3.6.4 HEATING THE HYDRAULIC OIL.................................................................................115 3.6.5 HOW TO MOVE THE MACHINE (ISO PATTERN CONTROL SYSTEM)......................................................115 3.6.5.1 STEERING (CHANGING DIRECTION).......................................................................117 3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM).................................................119 3.6.6.1 STEERING (CHANGING DIRECTION).......................................................................121 3.6.7 MOVING ON SLOPES..........................................................................................123 3.6.8 MAXIMUM IMMERSION DEPTH...................................................................................124 3.7 PARKING THE MACHINE.............................................................................................125 3.7.1 PARKING ON LEVEL GROUND...................................................................................125 3.7.2 PARKING ON SLOPES.........................................................................................126 3.8 STOPPING THE ENGINE.............................................................................................127 3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES......................................................................128 3.9.1 LOADING AND UNLOADING THE MACHINE.........................................................................128 3.9.2 TRANSPORT.................................................................................................129 3.10 HOW TO LIFT THE MACHINE........................................................................................130 3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON.....................................................................131 3.11.1 FUEL AND LUBRICANTS......................................................................................131 3.11.2 COOLANT..................................................................................................131 3.11.3 BATTERY..................................................................................................132 3.11.4 OTHER PRECAUTIONS........................................................................................132 3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...............................................................132 3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON.....................................................................133 3.13 USING THE WORK EQUIPMENT.......................................................................................134 3.13.1 LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE........................................................134 3.13.2 ORGANIZING THE WORK AREA.................................................................................135 3.13.3 LOADING MATERIAL ON HEAPS AND ON LEVEL SURFACES..........................................................136 3.13.4 LOADING MATERIAL ON SLOPES...............................................................................137 3.13.5 DIGGING METHOD...........................................................................................138 3.13.6 CHANGING THE BUCKET WITH STANDARD RAPID COUPLING.........................................................139 3.13.6.1 RELEASING THE BUCKET...............................................................................140 3.13.6.2 COUPLING THE BUCKET................................................................................140 3.13.7 CHANGING THE BUCKET WITH OPTIONAL RAPID COUPLING.........................................................142 3.13.7.1 RELEASING THE BUCKET...............................................................................143 3.13.7.2 COUPLING THE BUCKET................................................................................143 3.14 LONG PERIODS OF INACTIVITY.....................................................................................145 3.14.1 BEFORE THE PERIOD OF INACTIVITY..........................................................................145 3.14.2 DURING THE PERIOD OF INACTIVITY..........................................................................146 3.14.3 AFTER THE PERIOD OF INACTIVITY...........................................................................146 3.15 TROUBLESHOOTING................................................................................................147 3.15.1 HOW TO REMOVE THE MACHINE................................................................................147 3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED.................................................................147 3.15.3 IF THE BATTERY IS DEPLETED...............................................................................148 3.15.3.1 STARTING WITH BOOSTER CABLES.......................................................................149 3.15.4 OTHER TROUBLES...........................................................................................150 3.15.4.1 ELECTRICAL CIRCUIT.................................................................................150 3.15.4.2 HYDRAULIC SYSTEM...................................................................................151 3.15.4.3 ENGINE.............................................................................................152 3.15.4.4 HYDROSTATIC TRANSMISSION...........................................................................153 4.1 GUIDE TO MAINTENANCE............................................................................................156 4.2 MAINTENANCE NOTES...............................................................................................158 4.2.1 NOTES REGARDING THE ENGINE................................................................................158 4.2.1.1 ENGINE OIL..........................................................................................158 4.2.1.2 COOLANT.............................................................................................158 4.2.1.3 FUEL................................................................................................159 4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM......................................................................159 4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM.....................................................................160 4.2.4 NOTES REGARDING LUBRICATION...............................................................................160 4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING.....................................................161 4.3 FUEL, COOLANT AND LUBRICANTS....................................................................................162 4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES..................................................164 4.4 DRIVING TORQUES FOR SCREWS AND NUTS.............................................................................165 4.4.1 STANDARD DRIVING TORQUES..................................................................................165 4.4.2 SPECIFIC DRIVING TORQUES..................................................................................165 4.5 LUBRICATION.....................................................................................................166 4.5.1 LUBRICATION DIAGRAM.......................................................................................166 4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY.......................................................167 4.6.1 CRITICAL PARTS FOR SAFETY.................................................................................168 FUEL SUPPLY SYSTEM..........................................................................................168 STANDARD HYDRAULIC SYSTEM...................................................................................169 HIGH-FLOW HYDRAULIC SYSTEM..................................................................................171 OPERATORíS SAFETY...........................................................................................173 4.7 MAINTENANCE PLAN................................................................................................174 4.7.1 WHEN REQUIRED.............................................................................................177 4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE............................................177 4.7.1.b TYRE ROTATION.......................................................................................178 4.7.1.c WASHING THE COOLING CIRCUIT.........................................................................179 4.7.1.d DRAINING THE FUEL TANK..............................................................................180 4.7.1.e RELEASING THE PARKING BRAKE.........................................................................181 4.7.2 CHECKS BEFORE STARTING....................................................................................182 4.7.2.a VARIOUS CHECKS......................................................................................182 4.7.2.b CHECKING THE COOLANT LEVEL..........................................................................182 4.7.2.c CHECKING THE FUEL LEVEL.............................................................................183 4.7.2.d CHECKING THE ENGINE OIL LEVEL.......................................................................184 4.7.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT.....................................................185 4.7.2.f CHECKING THE FUEL FILTER FOR SEDIMENTS AND WATER....................................................186 4.7.2.g CHECKING THE WIRING SYSTEM..........................................................................186 4.7.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION.........................................................187 4.7.4 MAINTENANCE EVERY 50 HOURS OF OPERATION...................................................................187 4.7.4.a CHECKING THE TYRE PRESSURE..........................................................................187 4.7.4.b CHECKING THE COOLANT LEVEL IN THE RADIATOR..........................................................187 4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION........................................................188 4.7.6 MAINTENANCE EVERY 250 HOURS OF OPERATION..................................................................188 4.7.6.a ADJUSTING THE FAN BELT TENSION......................................................................188 4.7.6.b CHECKING THE BATTERY ELECTROLYTE LEVEL..............................................................189 4.7.6.c CHECKING THE GEARING CHAIN TENSION..................................................................190 4.7.6.d CLEANING THE OUTSIDE OF THE RADIATORS...............................................................191 4.7.6.e CHECKING THE WHEEL NUT DRIVING TORQUE...............................................................192 4.7.6.f CHECKING THE OIL LEVEL IN THE FINAL TRANSMISSIONS...................................................192 4.7.6.g LUBRICATING THE JOINTS..............................................................................193 4.7.6.h CHANGING THE ENGINE OIL.............................................................................194 4.7.6.j CHANGING THE ENGINE OIL FILTER......................................................................195 4.7.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines filled with synthetic...............196 4.7.8 MAINTENANCE EVERY 500 HOURS OF OPERATION..................................................................196 4.7.8.a CHANGING THE FUEL FILTER............................................................................196 4.7.8.b CHANGING THE HYDRAULIC OIL DRAIN FILTER.............................................................198 4.7.8.c CHANGING THE FUEL PUMP PRECLEANER...................................................................199 4.7.8.d DRAINING THE HYDRAULIC OIL TANK (Only for machines filled with synthetic biodegradable oi...........200 4.7.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION.................................................................202 4.7.9.a CHANGING THE OIL IN THE FINAL TRANSMISSION..........................................................202 4.7.9.b CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER...................................203 4.7.9.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE...................................................205 4.7.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION................................................................206 4.7.10.a CHANGING THE COOLANT...............................................................................206 4.7.10.b CHANGING THE SUCTION FILTER........................................................................208 4.7.10.c CHECKING THE ALTERNATOR AND THE STARTER............................................................209 5.1 TECHNICAL DATA..................................................................................................212 5.1.1 STANDARD MACHINE OVERALL DIMENSIONS.......................................................................212 5.1.2 MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT........................................................214 5.1.3 TECHNICAL CHARACTERISTICS.................................................................................216 6.1 AUTHORIZED OPTIONAL EQUIPMENT...................................................................................220 6.1.1 PRECAUTIONS REGARDING SAFETY..............................................................................220 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT.......................................................221 6.1.3 CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT................................................222 6.1.4 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION WITH HIGH-FLOW HYDRAULIC S...............223 6.2 CHANGING THE AUTHORIZED EQUIPMENT...............................................................................224 6.2.1 CONNECTING THE EXCAVATOR..................................................................................224 6.2.2 CONNECTING THE HYDRAULIC CIRCUIT..........................................................................225 6.2.3 CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK..........................................227 6.2.4 PREPARING THE MACHINE FOR THE USE OF THE EXCAVATOR........................................................228 6.2.5 USING THE MACHINE WITH THE EXCAVATOR......................................................................228 6.3 PALLET FORKS....................................................................................................229
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