KMW 1220 Manuel utilisateur

1220/1220HL

KMWLtd. 198N.Hwy281 GreatBend, Kansas67530 800445-7388 Fax620793-6737 www.kmwloaders.com

Mid-Mount Loader

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This Manual Must Be Delivered

To The Owner At time Of Machine Delivery.

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OPERATOR INSTALLATION

& PARTS MANUAL

2503-1181

Rev. E

May 2014

Printed in the U.S.A.

FOREWORD

You are now the proud owner of a KMW Loader. This loader is a product of KMW

quality engineering and manufacturing. It is made of fine materials and under a

rigid quality control system. It will give you long, satisfactory service. To obtain

the best use of your loader, please read this manual carefully. It will help you

become familiar with the operation of the loader and contains many helpful hints

about loader maintenance. It is KMW’s policy to utilize as quickly as possible

every advance in our research. The immediate use of new techniques in the

manufacture of products many cause some small parts of this manual to be

outdated. KMW dealers will have the most up-to-date information. Please do not

hesitate to consult with them.

SAFETY FIRST

This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual

and on labels on the front loader itself to warn of the possibility of personal injury.

Read these instructions carefully. It is essential that you read the instructions and

safety regulations before you attempt to assemble or use this unit.

DANGER:

Indicates an imminently hazardous situation

which, if not avoided, will result in death or

serious injury.

WARNING:

Indicates a potentially hazardous situation which,

if not avoided, could result in death or serious

injury.

CAUTION:

Indicates a potentially hazardous situation which,

if not avoided, may result in minor or moderate

injury.

IMPORTANT:

Indicates that equipment or property damage

could result if instructions are not followed.

NOTE:

Gives helpful information

SAFETY PRECAUTIONS

Most loader equipment accidents can be avoided by following simple safety precautions. These safety

precautions, if followed at all times, will help you operate your loader safely.

Understand that your safety and the safety of other persons is measured by how you service and operate this

loader. Know the position and operations of all controls before you try to operate. Make sure you check all

controls in a safe area before starting your work.

The safety information given in this manual does not replace safety codes, insurance requirements, federal,

state, and local laws. Make sure your machine has the correct equipment required by your local laws and

regulations.

1. Read and understand both the tractor and the loader Operator Manuals before using the loader. Lack of

knowledge can lead to accidents.

2. It is the loader owner’s responsibility to make sure anyone operating the loader reads and understands this

manual first before operating the machine.

3. The tractor should be equipped with an approved rollover-protective structure (ROPS) or ROPS Cab and seat

belt. Use seat belt as specified by tractor/ROPS manufacturer.

4. Do not lift or carry anybody on the loader, bucket or attachment.

5. Do not allow bystanders in loader work area.

6. Never allow anyone to get under the loader bucket or attachment or reach through the loader boom when the

bucket or attachment is raised.

7. Do not walk or work under a raised loader bucket or attachment unless it is securely blocked and held in

position.

8. Use extreme caution when operating on a slope; always operate up and down the slope, never across the

slope.

9. Add wheel ballast and/or rear weight to counterbalance tractor/loader for stability at maximum loader capacity.

Additional counterweight requirements will vary with loader attachments and equipment application.

10. Move the wheels to the tractor manufacturer’s widest recommended settings to increase stability.

11. For better stability, always use a tractor equipped with a wide front axle, never use a tractor equipped with a

tricycle type front axle.

12. Move and turn the tractor at low speeds.

13. Never travel at high speeds with bucket loaded.

14. Carry loader boom at a low position during normal operation.

15. Use caution when operating the loader with a raised bucket or attachment.A raised loader changes the center

of gravity of the machine and increases the possibility of tip over.

16. Avoid driving over loose fill, rocks, holes, or anything that may be dangerous for loader operation or

movement.

17. Avoid overhead wires and obstacles when loader bucket or attachment is raised. Electrocution can occur with

or without contact.

18. Check for underground utilities before digging below grade level.

19. Allow for the loader length when making turns.

20. Gradually stop the loader boom when lowering or lifting.

21. Use caution when handling loose or unstable loads.

22. When servicing the loader or leaving operator's seat for any reason, always:

A. Lower the loader to ground.

B. Turn on Comfort Drive, if equipped

C. Apply the parking brake securely

D. Shut off the engine

E. Turn on tractor switch so Comfort Drive Solenoid is energized.

F. Release all hydraulic pressure in all circuits by moving hydraulic control lever or levers in all positions.

G. Return lever or levers to neutral position.

H. Turn off tractor switch and remove the key.

23. Operate the loader controls only when properly sitting on the tractor seat.

24. Visually check for hydraulic leaks and broken, missing, or malfunctioning parts. Make necessary repairs

before operation.

25. Escaping hydraulic fluid under pressure can have sufficient force to penetrate the skin, causing serious

personal injury. Do not use HANDS to search for suspected leaks. If injured by escaping fluid, obtain medical

treatment immediately.

26. Before disconnecting hydraulic lines, relieve all hydraulic pressure.

27. Do not tamper with the relief valve setting.

28. Never use loader for handling large heavy objects, such as large round or rectangular bales, logs, and oil

drums unless loader is equipped with attachment that is designed to handle such objects.

29. Handling large heavy objects can be extremely dangerous due to:

A. Danger of rolling the tractor over.

B. Danger of upending the tractor.

C. Danger of the object rolling or sliding down the loader boom onto the operator.

30. If you must handle large heavy objects, protect yourself by:

A. Using caution, moving slowly, and avoiding bumps and rough ground.

B. Never lifting the load higher than necessary to clear the ground.

C. Adding rear ballast to the tractor to compensate for the load.

D. Never lifting large heavy objects that may roll or fall on the operator.

31. Operate the tractor and loader such that complete control and machine stability is maintained at all times.

32. Always wear safety goggles when servicing or repairing the machine.

33. When servicing or replacing pins in cylinder ends, bucket, etc., always use a brass drift and hammer. Failure

to do so could result in injury from flying metal fragments.

34. Replace damaged or illegible safety labels. See following pages for required labels.

35. Do not modify, alter, or permit anyone else to modify or alter the loader, any of its components, or any loader

function without first consulting a KMW dealer.

36. Assemble, remove, and reinstall the loader only as directed in this manual. Failure to do this could result in

serious personal injury or death.

37. Never tow from any point of the loader with a chain, rope, or cable. Doing so could cause a roll over or

serious damage to the loader.

38. Never lift any load from any point of the loader with a chain, rope, or cable unless loader is equipped with a

KMW factory approved attachment which was designed and built for this type of lifting. Always follow lifting

instructions included with these attachments.

39. When a front loader is mounted on the tractor, enter and exit the operator’s seat only from left side of tractor.

40. Always park loader with a KMW attachment attached to the loader.

41. Special care should be taken to park or store attachments with points or sharp edges in a safe manner.

42. Make sure all parked loaders are on a hard level surface. Engage all safety devices to prevent loader from

falling and being damaged or injuring someone. Do not repair loader if it is not mounted on the tractor. Loss of

hydraulic fluid or removal of parts could cause loader to collapse resulting in injury.

43. Before starting engine, be sure all operating controls are in neutral or park lock position.

44. When using remote hydraulic tractor valves on some tractors, the loader lift and dump cylinders will continue

moving unless the control lever/levers are manually returned to neutral, or until relief pressure is reached at

the ends of piston strokes. Observe the bucket or attachment movement and maintain control with the

lever/levers.

45. Be certain lights and safety markings as provided by the tractor manufacturer are clean and operating when

transporting the tractor/loader on public roads. Be certain that the Slow Moving Vehicle (SMV) emblem is

visible. Check with local law enforcement for specific requirements.

46. When using a loader be alert of bucket or attachment position at all times. Loader in raised position with

attachment rolled back can dump material onto tractor causing damage or injury to tractor and/or operator.

47. The loader may shift during shipping and handling, making it unstable on the pallet. Support loader with an

overhead hoist or other suitable means prior to removing bands or attaching straps securing loader to pallet.

Failure to do so could result in accidental tip-over of the loader that could cause serious injury to you and/or

bystanders.

48. Do not service the loader while the tractor engine is running.

49. Do not use the loader to raise the tractor in order to perform service on the tractor and/or the loader.

50. Always turn on Accumulator (Comfort Drive), lower loader/attachment to ground and relieve hydraulic

pressure from system, before servicing unit. Failure to follow these instructions could result in personal injury.

51. Do not operate without confirmation that coupler pins are fully engaged. Loader attachment can fall off if not

properly attached. To avoid serious injury or death:

A. Only use loader manufacturer approved attachments.

B. Read all operators manuals and decals before operating. Follow all safety operating, and service

instructions. Contact dealer for replacement parts.

52. Never turn comfort drive on while tractor is moving. Loader movement could cause loader to lower causing

attachment or material being moved to contact ground. Failure to follow these instructions could result in personal

injury or property damage.

SAFETY DECALS

Located on the loader hose cover.

Located on Accumulator Mounting Plate.

See Comfort Drive Section.

SAFETY DECALS

Safety Decal Locations

Important: Safety decals 0595-3000, 0595-3001, 0595-3003,

and 0595-3004 are located on the loader LH side and are

visible as you mount the tractor. Important decal 0595-3087 is

located on LH center mount bracket assembly. 0595-3051

Warning decal is Located on Quick Attach.

Care of Safety Decals

1. Keep safety decals clean and free of obstructing

material.

2. Clean safety decals with soap and water and dry with a

soft cloth.

3. Replace damaged or missing safety decals with new

decals from your KMW Dealer.

4. If a component with a safety decal(s) affixed is replaced

with a new part, make sure new safety decal(s) are

attached in the same location(s) as the replaced

components.

5. Mount new safety decals by applying on a clean dry

surface and pressing air bubbles to outside edges.

0595-3062

0595-3000

0595-3003

0595-3001

0595-3004

TABLE OF CONTENTS

1. INTRODUCTION..................................................9

2. LIMITED WARRANTY STATEMENT.................10

3. ITEMS NOT COVERED UNDER WARRANTY .11

4. WARRANTY RESPONSIBILITIES ....................12

5. SPECIFICATIONS..............................................13

5.1. SPECIFICATIONS OF LOADER ..............13

5.2. BUCKET SPECIFICATIONS.....................13

6. INSTALLATION INSTRUCTIONS......................14

6.1. TRACTOR PREPARATION.......................14

6.2. INSTALLATION.........................................16

6.3. CONNECT HYDRAULIC HOSES TO

LOADER HOSE CIRCUITS....................17

6.4. LOADER INSTALLATION .........................19

7. PRE-OPERATION INSTRUCTIONS..................21

7.1. TRANSMISSION FLUID ...........................21

7.2. INITIAL LOADER OPERATION ................21

7.3. EXTERNAL LOADER AND/OR TRACTOR

VALVE.....................................................21

7.4. LOADER MOUNTED CONTROL VALVE

EQUIPPED WITH SINGLE LEVER

CONTROL HANDLE or TRACTOR

REMOTE VALVE EQUIPPED WITH

SINGLE LEVER CONTROL HANDLE....21

7.5. TRACTOR REMOTE VALVE EQUIPPED

WITH 2 OR 3 CONTROL HANDLES......22

7.6. NEUTRAL POSITION ...............................22

7.7. FLOAT POSITION.....................................22

7.8. REGENERATIVE DUMPING POSITION..22

7.9. RELIEF CARTRIDGE ...............................23

7.10. LOAD SENSE LOADER VALVE .............23

7.11. INITIAL LOADER OPERATION...............23

7.12. REMOVING AIR FROM HYDRAULIC

SYSTEM .................................................23

7.13. RELIEF NOISE .......................................23

7.14. HOSE IDENTIFICATION.........................23

7.15. BUCKET LEVEL INDICATOR.................24

8. DAILY MAINTENANCE & LUBRICATION ........25

8.1. DAILY CHECKS........................................25

8.2. LOADER LUBRICATION ..........................26

8.3. LOADER EQUIPPED WITH OPTIONAL

GRILL GUARD........................................28

8.4. SKID STEER QUICK ATTACH

LUBRICATION........................................29

1. Park bucket or attachment...............................29

9. OPERATING INSTRUCTIONS ..........................30

9.1. FILLING THE BUCKET.............................30

9.2. CARRYING THE LOAD............................30

9.3. DUMPING THE BUCKET..........................31

9.4. LOWERING THE BUCKET.......................31

9.5. OPERATING WITH FLOAT CONTROL....31

9.6. LOADING FROM A BANK.........................31

9.7. PEELING AND SCRAPING ......................32

9.8. LOADING LOW TRUCKS OR SPREADERS

FROM A PILE..........................................32

9.9. BACKFILLING...........................................32

9.10. HANDLING LARGE HEAVY OBJECTS..33

9.11. BACK GRADING.....................................33

9.12. PROHIBITED OPERATIONS..................34

10. DISMOUNTING THE LOADER........................35

11. MOUNTING THE LOADER..............................39

12. SKID STEER TOOL CARRIER SYSTEM........42

12.1. RECOMMENDED LOADER FACTORY

APPROVED ATTACHMENTS.................42

12.2. NON-LOADER FACTORY

ATTACHMENTS......................................42

12.3. SKID STEER TOOL CARRIER SYSTEM

SERVICE & LUBRICATION....................43

13. INSTALLATION & OPERATION OF SKID

STEER TOOL CARRIER SYSTEM .................44

13.1. INSTALLATION INSTRUCTIONS...........44

13.2. SKID STEER TOOL CARRIER HANDLES

IN DISENGAGED POSITION .................44

13.3. SKID STEER TOOL CARRIER HANDLES

IN ENGAGED POSITION .......................44

14. INSTALLING BUCKET OR ATTACHMENT TO

SKID STEER TOOL CARRIER .......................45

14.1. OPERATING INSTRUCTIONS ...............45

15. REMOVING BUCKET OR ATTACHMENT

FROM SKID STEER TOOL CARRIER............48

15.1. OPERATING INSTRUCTIONS ...............48

16. SKID STEER BUCKET ....................................49

16.1. SKID STEER BUCKET ...........................49

16.2. INSTALLATION INSTRUCTIONS TO SKID

STEER TOOL CARRIER ........................49

17. SKID STEER BALE SPEAR............................50

17.1. SKID STEER BALE PROBE...................51

17.2. ASSEMBLY INSTRUCTIONS .................51

17.3. INSTALLATION INSTRUCTIONS TO SKID

STEER QUICK ATTACH.........................51

17.4. OPERATING INSTRUCTIONS ...............51

18. SKID STEER PALLET FORK ..........................52

18.1. SKID STEER PALLET FORK..................53

18.2. ASSEMBLY INSTRUCTIONS .................53

18.3. INSTALLATION INSTRUCTIONS TO SKID

STEER QUICK ATTACH.........................53

18.4. OPERATING INSTRUCTIONS...............53

18.5. PARKING INSTRUCTIONS....................53

19. OPTIONAL ORIFICE KIT.................................54

20. OPTIONAL ORIFICE KIT.................................55

21. LEAK DOWN INSPECTION ............................56

21.1. FRONT END LOADER FIELD LEAK

DOWN INSPECTION AND TEST...........56

21.2. LEAKAGE TEST FOR LIFT CYLINDER

SEALS (Open Center Systems)..............57

21.3. LEAKAGE TEST FOR LIFT CIRCUIT

LOADER VALVE SPOOL........................59

21.4. LEAKAGE TEST FOR TILT OR BUCKET

CYLINDER, SEALS ................................59

21.5. TILT OR BUCKET CYLINDER VALVE

SPOOL LEAKAGE..................................60

21.6. ACCEPTABLE LIFT CYLINDER LEAK

DOWN RATES........................................61

21.7. ACCEPTABLE TILT OR BUCKET

CYLINDER LEAK DOWN RATES ..........61

22. TROUBLE SHOOTING PROCEDURES..........62

22.1. TROUBLE SHOOTING FOR ALL

LOADERS...............................................62

22.2. TROUBLE SHOOTING OPTIONAL

LOADER VALVE .....................................65

22.3. TROUBLE SHOOTING OPTIONAL

COMFORT DRIVE..................................66

23. TORQUE CHART.............................................67

24. PARTS MANUAL .............................................68

25. DECALS & MANUALS ....................................69

26. BOOM ASSEMBLY..........................................72

27. HYDRAULIC CYLINDERS, HOSES, AND

TUBELINES.....................................................74

28. LIFT CYLINDER (CROSS)...............................76

29. TILT CYLINDER (BAILEY) ..............................77

30. MID MOUNT COUPLER KIT............................78

31. LOADER VALVE 2 SPOOL (Load Sense)......80

32. LOADER VALVE 2 SPOOL (Open/Closed

Center).............................................................82

33. JOYSTICK CONTROLLER..............................84

34. SKID STEER BUCKET ....................................85

35. LOADER VALVE ..............................................86

36. CONTROL HANDLE COMPONENTS.............88

37. SKID STEER TOOL CARRIER ATTACHMENT91

38. SKID STEER BALE SPEAR............................94

39. BUCKET LEVEL INDICATOR..........................95

40. SKID STEER PALLET FORK ..........................96

41. OPTIONAL ORIFICE KITS ..............................98

NOTES:

1. INTRODUCTION

This manual provides safety, set-up, operation, maintenance, removing, storing,

and reinstalling instructions for your new mid-mount loader.

Your loader has been designed to give many years of satisfactory service.

Successful operation and long life of the loader depends, of course, on proper

operation and care. Please read this manual carefully and follow the instructions.

Correct operation and maintenance will save much time and expense.

OBSERVE and follow all CAUTION, WARNING, and DANGER instructions to

help prevent personal injury and damage to the loader.

The reference to left hand and right hand used in this manual refers to the

position when standing at the rear of the unit and facing forward.

If, at any time, you have a service problem with your loader or need new parts,

contact your local KMW dealer. Your dealer will need the loader model number

and serial number to give you prompt, efficient service. The serial number plate is

located on the inside plate of the left hand bearing box.

KMW LOADER

MODEL NUMBER

SERIAL NUMBER

DATE OF PURCHASE

NAME OF DEALER

2. LIMITED WARRANTY STATEMENT

KMW Ltd., herein referred to as KMW, warrants each new KMW product to be free from

defects in material and workmanship. This warranty is applicable only for the normal

service life expectancy of the product, not to exceed 12 consecutive months for all

hydraulic components and loader attachments and 24 consecutive months on all other

loader components from the date of delivery of the new KMW product to the original

purchaser.

Genuine KMW replacement parts and components will be warranted for 90 days from

date of purchase, or the remainder of the original equipment warranty period, whichever

is longer.

Under no circumstances will it cover any merchandise or components thereof, which, in

the opinion of the company, has been subjected to misuse, unauthorized modifications,

alteration, an accident or if repairs have been made with parts other than those obtained

through KMW. Additionally, the warranty shall only be effective if the owner/dealer

responsibilities contained herein are adhered to.

The company in no way warrants tractors, engines, batteries, tires or other trade

accessories since these items may be warranted separately by their respective

manufacturer and are not manufactured by KMW.

Our obligation under this warranty shall be limited to repairing or replacing, free of

charge to the original purchaser, any part that, in our judgement, shall show evidence of

such defect, provided further that such part shall be returned within thirty (30) days from

date of failure to KMW routed through the dealer from whom the purchase was made,

transportation charges prepaid and the other conditions hereof are complied with.

This warranty shall not be interpreted to render KMW liable for injuries or damages of

any kind or nature to person or property. This warranty does not extend to the loss of

crops, loss because of delay in harvesting, or any expense or loss incurred for labor,

substitute machinery, rental or for any other reason.

Except as set forth herein, KMW shall have no obligation or liability of any kind on

account of any of its equipment and shall not be liable for special or consequential

damages. KMW makes no other warranty, expressed or implied, and, specifically, KMW

disclaims any implied warranty or merchantability or fitness for a particular purpose.

Some states or provinces do not permit limitation or exclusions of implied warranties or

incidental or consequential damages, so the limitations or exclusion in this warranty may

not apply in those areas only.

This warranty is subject to any existing conditions of supply, which may directly affect our

ability to obtain materials or manufacture replacement parts.

KMW reserves the right to make improvements in design or changes in specifications at

any time, without incurring any obligation to owners of units previously sold. No one is

authorized to alter, modify or enlarge this warranty nor the exclusion, limitations and

reservations. Other restrictions, conditions and responsibilities with respect to the

warranty are set forth in the following pages and are fully applicable to the warranty

herein provided.

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