Komatsu WA20-2 Operation & Maintenance Manual
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Komatsu WA20-2 Operation & Maintenance Manual

Komatsu WA20-2 Operation & Maintenance Manual

Wheel loader
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Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or maintain-
ing this machine. This manual should be kept near the
machine for reference and periodically reviewed
by all personnel who will come into contact with it.
Komatsu has Operation & Maintenance Manuals written in
some other languages. If a foreign language manual is
necessary, contact your local distributor for availability.
WA20
WA40
WHEEL LOADER
SERIAL NUMBERS
NOTICE
,WA30
-2
,WA50
-3
WA20 - 11270
WA30 - 18970
and up
WA40 - 13530
WA50 - 20642
SEAM010700
-5
-3

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Do you have a question about the WA20-2 and is the answer not in the manual?

Questions and answers

Richard Dick
March 20, 2025

Loader drives good When cold won’t climb a little hill when warm

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1 comments:
Mr. Anderson
May 14, 2025

A Komatsu WA20-2 loader that drives well when cold but struggles to climb a small hill when warm could be experiencing hydraulic or engine performance issues related to temperature. As the machine warms up, hydraulic fluid may thin out if it's not the correct viscosity, reducing power to the drive system. Similarly, engine performance may drop due to overheating or fuel system problems affected by temperature. Low-viscosity oil or improper coolant use in warm conditions could also reduce efficiency, leading to difficulty climbing hills.

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Summary of Contents for Komatsu WA20-2

  • Page 1 NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.

  • Page 2: Foreword

    This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.

  • Page 3: Safety Information

    Safety precautions are described in SAFETY from page 1-1. Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions.

  • Page 4: Introduction

    If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user.

  • Page 5: Location Of Plates, Table To Enter Serial No. And Distributor

    4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 4.1 MACHINE SERIAL NO. PLATE POSITION 4.1.1 WA20 Position of plate This plate is on the center of the front frame on the right side of the machine. Position of stamp This is stamped on the center of the front frame on the right side of the machine.
  • Page 6 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No.: Engine serial No.: Distributor name: Address: Phone: Service personnel for your machine: REMARKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...

  • Page 7: Table Of Contents

    5. CONTENTS 1. Foreword ............................. 0- 1 2. Safety information ..........................0- 2 3. Introduction ............................0- 3 4. Location of plates, table to enter serial No. and distributor ............0- 4 SAFETY 6. General precautions ..........................1- 2 7. Precautions during operation ......................1- 7 Before starting engine ......................
  • Page 8 5. CONTENTS 5. CONTENTS 12. Operation .............................. 2-18 12.1 Check before starting engine ....................2-18 12.2 Starting engine .......................... 2-29 12.3 Operations and checks after starting engine ................. 2-32 12.4 Moving machine off ........................2-34 12.5 Changing direction ........................2-36 12.6 Turning ............................
  • Page 9 5. CONTENTS 5. CONTENTS MAINTENANCE 17. Guides to maintenance ........................3- 2 18. Outlines of service ..........................3- 5 18.1 Outline of oil, fuel, coolant ...................... 3- 5 18.2 Outline of electric system ......................3- 8 19. Wear parts list ............................. 3- 9 20.

  • Page 10: Safety

    SAFETY 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 equip- ment and attachments.

  • Page 11: General Precautions

    WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. SAFETY RULES ‡ ONLY trained and authorized personnel can operate and maintain the machine. ‡ Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
  • Page 12 UNAUTHORIZED MODIFICATION ‡ Any modification made without authorization from Komatsu can create hazards. ‡ Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modification. ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT ‡...
  • Page 13 WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. FIRE PREVENTION FOR FUEL AND OIL Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS. ‡ Keep flame away from flammable fluids. ‡...
  • Page 14 WARNING: Failure to follow these safety precautions may lead to a serious accident. 6. GENERAL PRECAUTIONS ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled. If you handle materials containing asbestos fibers, follow these guidelines as given below: ‡...
  • Page 15 The Komatsu ROPS fulfills all of the regulations and standards for all countries, but if it is rebuilt without authorization or is damaged when the machine rolls over, the strength will drop and it will not be able to fulfill its function properly.

  • Page 16: Precautions During Operation

    7. PRECAUTIONS DURING WARNING: Failure to follow these safety OPERATION precautions may lead to a serious accident. 7.1 BEFORE STARTING ENGINE SAFETY AT WORKSITE ‡ Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. ‡...
  • Page 17 WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. VENTILATION FOR ENCLOSED AREAS ‡ If it is necessary to start the engine within an enclosed area, provide adequate ventilation. Exhaust fumes from the engine can KILL. A0055060 PRECAUTIONS FOR MIRRORS, WINDOWS AND LIGHTS ‡...

  • Page 18: Operating Machine

    WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.2 OPERATING MACHINE WHEN STARTING ENGINE ‡ Walk around your machine again just before mounting it, checking for people and objects that might be in the way. ‡...
  • Page 19 WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. PRECAUTIONS WHEN TRAVELING ‡ It is dangerous to look around you when carrying out operations. Always concentrate on your work. ‡ Excessive speed, sudden starting, sudden stopping, sudden turns, and coasting when traveling are dangerous.
  • Page 20 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES ‡ Going close to high-voltage cables can cause electric shock. Always maintain the safe distance given below between the machine and the electric cable. ‡...
  • Page 21 WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. OPERATE CAREFULLY ON SNOW ‡ When working on snow or icy roads, there is danger that the machine may slip to the side on even the slightest slope, so always travel slowly and avoid sudden starting, turning, or stopping. ‡...
  • Page 22 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION PARKING THE MACHINE ‡ When parking the machine, stop on a flat firm road surface where there is no danger of falling rocks, landslides, or floods, and lower the work equipment to the ground. If the machine must be stopped on a slope, block the wheels to prevent the machine from moving.

  • Page 23: Transportation

    WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. 7.3 TRANSPORTATION LOADING AND UNLOADING ‡ Loading and unloading the machine always involves potential hazards. EXTREME CAUTION SHOULD BE USED. When loading or unloading the machine, run the engine at low idling and travel at low speed. ‡...

  • Page 24: Battery

    WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.4 BATTERY BATTERY HAZARD PREVENTION ‡ Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water. ‡...

  • Page 25: Towing

    WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. 7.5 TOWING WHEN TOWING, FIX WIRE TO HITCH PIN ‡ Towing in the wrong way may lead to serious personal injury or damage. ‡ When using another machine to tow this machine, use a wire rope with ample strength for the weight of this machine.

  • Page 26: Precautions For Maintenance

    ‡ ALWAYS attach the WARNING TAG to the control lever in the operator’s cab to alert others that you are working on the machine. Attach additional warning tags around the machine, if necessary. ‡ These tags are available from your Komatsu distributor. (Part No. 09963-03000) DO NOT operate When this plate is not being used keep it in the storage compartment.
  • Page 27 WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ‡ Replace the following fire-related components periodically: Fuel system: Fuel hose, spilling hose, and fuel tube cap Hydraulic system: Pump outlet hose ‡...
  • Page 28 WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE RULES TO FOLLOW WHEN ADDING FUEL OR OIL ‡ Always stop the engine before adding fuel or oil. ‡ Spilled fuel and oil may cause you to slip, so always wipe it up immediately. ‡...
  • Page 29 WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. PREVENTION OF FIRE Carrying out maintenance involves handling objects such as fuel and batteries which may cause a fire. To prevent fire, do as follows. ‡ Keep fuel and other flammable oil and fluids well away from fire. ‡...

  • Page 30: During Maintenance

    WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE 8.2 DURING MAINTENANCE PERSONNEL ‡ Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding, welding, and using a sledge-hammer. ATTACHMENTS ‡...
  • Page 31 WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. PRECAUTIONS WITH BATTERY ‡ When repairing the electrical system or when carrying out electrical welding, remove the negative (–) terminal of the battery to stop the flow of current. A0055170 HANDLING HIGH-PRESSURE HOSES ‡...
  • Page 32 WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE ‡ Immediately after stopping operations, the engine cooling water and oil at all parts is at high temperature and under high pressure.
  • Page 33 WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. WASTE MATERIALS ‡ Never dump waste oil in a sewer system, rivers, etc. ‡ Always put oil drained from your machine in containers. Never drain oil directly on the ground. ‡...

  • Page 34: Tires

    If you do not understand the proper procedure for carrying out maintenance or replacement of the wheel or tire, and you use the wrong method, the wheel or tire may burst and cause serious injury or damage. When carrying out such maintenance, please consult your Komatsu distributor or tire maker.
  • Page 35 WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. STORING TIRES AFTER REMOVAL ‡ As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires are stored outside, always erect a fence around the tires and put up “No Entry” and other warn- ing signs that even young children can understand.

  • Page 36: Position For Attaching Safety Labels

    There are other labels in addition to the safety labels listed as follows, so handle them in the same way. Safety labels may be available in languages other than English. To find out what labels are available, contact your Komatsu distributor. 9.1 POSITION FOR ATTACHING SAFETY LABELS 1-27...
  • Page 37 FAILURE TO FOLLOW THESE INSTRUCTIONS AND WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH. KEEP THE MANUALS NEAR THE MACHINE OPERATOR. FOR REPLACEMENT OF THEM WITH NEW ONES, CONTACT YOUR NEAREST KOMATSU AGENT. 2. Precautions for safety lock lever WARNING BEFORE LEAVING THE OPERATOR’S...
  • Page 38 9. POSITION FOR ATTACHING SAFETY LABELS 9. POSITION FOR ATTACHING SAFETY LABELS 4. Do not enter DANGER CRUSH HAZARD. CAN CAUSE SERVICE INJURY OR DEATH. WHEN MACHINE IS BEING OPERATED, NEVER PLACE YOURSELF IN ARTICULATED AREA OF MACHINE. 5. Precautions for safety bar 7.
  • Page 39 MEMO 1-30...

  • Page 40: Operation

    OPERATION...

  • Page 41: General View

    10. GENERAL VIEW 10.1 GENERAL VIEW OF MACHINE If directions are indicated in this section, they refer to the directions shown by the arrows in the diagram below. Machines equipped with canopy.

  • Page 42: General View Of Controls And Gauges

    10. GENERAL VIEW 10. GENERAL VIEW 10.2 GENERAL VIEW OF CONTROLS AND GAUGES...

  • Page 43: Explanation Of Components

    11. EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is impor- tant to understand fully the methods of operating the equipment and the meanings of the displays. 11.1 METER, LAMPS AL175252 1.
  • Page 44 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 3. TACHOMETER This indicates the revolution of engine. (graduated in 1000 rev.) 4. TURN SIGNAL PILOT LAMP When the turn signal lamp flashes, the pilot lamp also flashes. AE070320 5. FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank.
  • Page 45 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 8. HST OIL FILTER CLOGGING CAUTION LAMP This lamp indicates the end of life of HST oil filter. When lighting up, change to the new filter. This lamp tends to work when ambient temperature is low, however it is no problem when HST oil temperature gauge’s pointer is in white range.
  • Page 46 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 12. PREHEATING PILOT LAMP This informs the operator that the glow plug is heated. This lamp lights up when the starting switch is turned to the HEAT position, and goes out after 15 seconds. A0061050 13.

  • Page 47: Switches

    11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.2 SWITCHES 1. STARTING SWITCH This switch is used to start or stop the engine. OFF position The key can be inserted or withdrawn. The switches for the electric system are all turned off and the engine is stopped. ON position AM089390 Electric current flows in the charging and lamp circuits.
  • Page 48 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS REMARK When the key is turned to the ON position, all the pilot lamps except the preheating pilot lamp and parking brake reminder pilot lamp light up, so it is possible to check if the bulbs are blown. When the engine is running, all the pilot lamps except the parking brake pilot lamp go out.

  • Page 49: Control Levers, Pedals

    11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.3 CONTROL LEVERS, PEDALS 1. DIRECTIONAL LEVER This lever is used to change the direction of travel of the machine. The engine cannot be started if the directional lever is not at N (neutral).
  • Page 50 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 2. SAFETY LOCK (for directional lever) WARNING ‡ When leaving the operator's compartment, set the safety lock securely to the LOCK position. If the directional lever is not locked, and this is touched by mistake, this may lead to a serious accident.
  • Page 51 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 4. SAFETY LOCK (for work equipment control lever) WARNING ‡ When leaving the operator's compartment, set the safety lock securely to the LOCK position. If the control lever are not locked, and they are touched by mistake, this may lead to a serious accident.
  • Page 52 11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 7. PARKING BRAKE PEDAL WARNING Always apply the parking brake when leaving the machine or parking it. This lever operates the parking brake. The brake is applied by depressing this pedal, and the parking brake pilot lamp lights up.

  • Page 53: Cap With Lock

    11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.4 CAP WITH LOCK The fuel tank filler port is equipped with locks. Open and close the cap lock as follows. Use the starting key to open and close the cap. 11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK TO OPEN THE CAP 1.

  • Page 54: Tilt Hood

    11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.6 TILT HOOD When the lever on grill 1 is moved left, the tilt hood opens. When closing, move down the hood. 11.7 TOWING PIN 1. Align protrusion 1 in the towing pin with groove 2 in the counterweight, then insert and turn the pin 180°.

  • Page 55: Fusible Link

    11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.8.1 FUSE CAPACITY AND NAME OF CIRCUIT Fuse Name of circuit capacity F – R control Reverse lamp, Horn, Turn signal pilot lamp Bucket positioner Engine stop solenoid Light switch Monitor panel Parking buzzer Heater (front window) Front wiper, Room lamp, Patrol light...

  • Page 56: Manual Pocket

    11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS 11.10 MANUAL POCKET The operator’s seat has a manual pocket in the back of backrest. This manual should be kept in it for reference and periodical reviewing. 11.11 CONNECTORS Connectors 1 are in the right of the monitor panel. Use as power source.

  • Page 57: Operation

    Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
  • Page 58 Check for any loose or damaged bolts. If any loose bolts are found tighten them to 98 to 123 N•m (10 to 12.5 kgf•m, 72 to 90 lbft). If any bolts are damaged, replace them with genuine Komatsu bolts. 2-19...
  • Page 59 1. Turn the key in starting switch to the ON position. 2. When each pilot lamp 1 lights on, bulbs are no problem. 3. When each lamp doesn’t light, contact your Komatsu distributor for service. The preheating pilot lamp lights up only when the starting switch is at the HEAT position;...
  • Page 60 12. OPERATION 12. OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If you spill fuel, thoroughly clean up any spillage. 1. Turn the engine starting switch to the ON position, then check the fuel level with fuel gauge G.
  • Page 61 12. OPERATION 12. OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the tilt hood at the rear of the machine. 2. Remove dipstick G and wipe the oil off with a cloth. 3. Insert dipstick G fully in the oil filler pipe, then take it out again. 4.
  • Page 62 The play at the outside circumference of the steering wheel should be 20 – 40 mm (0.8 – 1.6 in). If it is more than 40 mm (1.6 in) or the operation of the steering is not smooth, please contact your Komatsu distributor for inspec- tion. 2-23...
  • Page 63 When carrying out walk-around checks or checks before starting, always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of the cause. 2-24...
  • Page 64 12. OPERATION 12. OPERATION CHECK SOUND OF HORN 1. Turn the starting switch 1 to ON. 2. Check for sound of horn by pushing the horn switch 2. CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE Check for lamps lighting. 1.
  • Page 65 12. OPERATION 12. OPERATION CHECK ENGINE EXHAUST COLOR AND SOUND CHECK OPERATION OF GAUGES CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE 2-26...
  • Page 66 12. OPERATION 12. OPERATION 12.1.3 ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT WARNING ‡ Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. ‡ Adjust the seat before starting operations or when changing operators.
  • Page 67 12. OPERATION 12. OPERATION 12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING If the control levers are touched by accident, the work equip- ment may move suddenly. When leaving the operator's com- partment, always set the safety lock securely to the LOCK position.

  • Page 68: Starting Engine

    12. OPERATION 12. OPERATION 12.2 STARTING ENGINE 12.2.1 NORMAL STARTING WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.
  • Page 69 12. OPERATION 12. OPERATION 12.2.2 STARTING IN COLD WEATHER WARNING ‡ Check that there are no persons or obstacles in the surround- ing area, then sound the horn and start the engine. ‡ Never use starting aid fluids as they may cause explosions. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.
  • Page 70 12. OPERATION 12. OPERATION 4. When engine starts, release the key of starting switch 1. The key will return automatically to the ON position. 5. When the engine speed rises, depress accelerator pedal 3 lightly and hold it in position. If the engine does not start, wait for 2 minutes, then repeat Steps AM090360 1, 2, and 3.

  • Page 71: Operations And Checks After Starting Engine

    12. OPERATION 12. OPERATION 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE WARNING ‡ Emergency stop If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position. ‡ If the work equipment is operated without warming the machine up sufficiently, the response of the work equipment to the movement of the control lever will be slow, and the work equipment may not move as the operator desires, so...
  • Page 72 12. OPERATION 12. OPERATION 3. Operate work equipment control lever 3 slowly to move the bucket cylinder and lift cylinder to the end of their stroke. 4. Operate the bucket and lift arm for 30 seconds each in turn. 5. After carrying out the warming-up operation, check that the gauges and pilot lamps are normal.

  • Page 73: Moving Machine Off

    12. OPERATION 12. OPERATION 12.4 MOVING MACHINE OFF WARNING When moving the machine off, check that the area around the machine is safe, then sound the horn before starting. Do not allow people near the machine. There is a blind spot behind the machine, so be particularly careful when traveling in reverse.
  • Page 74 12. OPERATION 12. OPERATION 5. Set safety lock 6 of directional lever 7 to the FREE position, then set directional lever 7 to the desired position. 6. Release brake pedal 4, then depress accelerator pedal 8 to move the machine off. REMARK When starting on a slope, depress the left brake pedal, then depress the accelerator pedal and slowly release the brake pedal to...

  • Page 75: Changing Direction

    12. OPERATION 12. OPERATION 12.5 CHANGING DIRECTION WARNING ‡ When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so be particularly careful when changing direction to travel in reverse. ‡...

  • Page 76: Stopping Machine

    12. OPERATION 12. OPERATION 12.7 STOPPING MACHINE WARNING ‡ Avoid stopping suddenly. Give yourself ample room when stopping. ‡ Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.

  • Page 77: Operation Of Work Equipment

    12. OPERATION 12. OPERATION 12.8 OPERATION OF WORK EQUIPMENT Work equipment control lever 1 can be used to operate the lift arm and bucket as follows. LIFT ARM OPERATION 1 Raise ( J ) 2 Hold ( N ): The lift arm is kept in the same position. 3 Lower ( M ) 4 Float ( * ): The lift arm moves freely under external force.

  • Page 78: Work Possible Using Wheel Loader

    12. OPERATION 12. OPERATION 12.9 WORK POSSIBLE USING WHEEL LOADER In addition to the following, it is possible to further increase the range of applications by using various attachments. 12.9.1 DIGGING OPERATIONS WARNING Always set the machine facing directly to the front when carrying out digging or scooping operations.
  • Page 79 12. OPERATION 12. OPERATION ‡ When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the machine forward. Always be careful not to load the bucket on one side and cause an unbalanced load. A suitable depth for each digging pass is 5 –...
  • Page 80 12. OPERATION 12. OPERATION 12.9.2 LEVELING OPERATIONS NOTICE Always operate the machine in reverse when carrying out leveling operations. If it is necessary to carry out leveling operations when traveling forward, do not set the bucket dumping angle to more than 20°. AE061970 1.
  • Page 81 12. OPERATION 12. OPERATION 12.9.5 LOADING OPERATIONS Select the method of operation which will give the minimum amount of turning and travel in order to provide the most efficient method for the jobsite. WARNING ‡ Always keep the working area flat. Do not turn suddenly or apply the brake suddenly when traveling with a raised load.

  • Page 82: Precautions For Operation

    If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine. NOTICE If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the parking brake checked for any abnormality. 12.10.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES LOWER THE CENTER OF GRAVITY WHEN TURNING.
  • Page 83 The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface. Contact your Komatsu distributor or tire dealer for information. ‡ The following is a guide to suitable tire pressures and speeds when traveling on a paved surface with standard tires.

  • Page 84: Adjusting Work Equipment Posture

    12. OPERATION 12. OPERATION 12.11 ADJUSTING WORK EQUIPMENT POSTURE WARNING ‡ Stop the machine on flat ground and put blocks in front and behind the wheels. ‡ Apply the parking brake. ‡ Secure the front and rear frames with the safety bar. ‡...

  • Page 85: Parking Machine

    12. OPERATION 12. OPERATION 12.12 PARKING MACHINE WARNING ‡ Avoid stopping suddenly. Give yourself ample room when stopping. ‡ Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.

  • Page 86: Checks After Completion Of Operation

    12. OPERATION 12. OPERATION 5. Release brake pedal 2. 6. Operate work equipment control lever 6 to lower the bucket to the ground. 7. Lock work equipment control lever 6 with safety lock 7. 12.13 CHECKS AFTER COMPLETION OF OPERATION Check the engine water temperature, engine oil pressure, HST oil temperature, and fuel level with the meter and lamps.

  • Page 87: Stopping Engine

    12. OPERATION 12. OPERATION 12.14 STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency. In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop 1.

  • Page 88: Handling The Tires

    fi When the bead is damaged fi For tubeless tires, when there is air leakage or improper repair Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. 12.17.2...
  • Page 89 12. OPERATION 12. OPERATION H – h Deflection ratio = x 100 As a guideline that can be checked visibly, the deflection ratio of the front tire (deflection/free height) is as follows. When carrying normal load (lift arm horizontal): Approx. 15 – 25% When digging (rear wheels off ground): Approx.
  • Page 90 12. OPERATION 12. OPERATION 12.17.3 REPLACING TIRES REMOVING TIRES 1. Lower the work equipment to the ground and apply the parking brake. 2. Loosen all wheel hub bolts 1 one turn. 3. Jack up the machine. 4. Remove wheel hub bolts 1, then replace the tire. INSTALLING TIRE 1.

  • Page 91: Transportation

    13. TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. 13.1 LOADING, UNLOADING WORK WARNING ‡ Make sure the ramp has sufficient width, length and thick- ness to enable the machine to be safely loaded and unloaded. ‡...

  • Page 92: Precautions For Loading

    NOTICE ‡ For weight, see “25. SPECIFICATIONS”. ‡ Specifications value indicates the standard specifications. When installing the attachment, or optional equipment, lifting method has been changed; consult Komatsu or your Komatsu distributor for details. 2-53...
  • Page 93 13. TRANSPORTATION 13. TRANSPORTATION 13.4.1 POSITION FOR ATTACHING HOOK MARK LABELS For details of the machine weight, see “25. SPECIFICATIONS”. 2-54...
  • Page 94 13. TRANSPORTATION 13. TRANSPORTATION 13.4.2 METHOD OF LIFTING MACHINE The machine can be lifted only if it has hook mark labels. When lifting the machine, stop the machine on level ground and do as follows. 1. Start the engine, set the machine horizontal, then set the work equipment to the travel posture (see “12.4 STARTING MA- CHINE”).

  • Page 95: Precautions For Transportation

    13. TRANSPORTATION 13. TRANSPORTATION 13.4 PRECAUTIONS FOR TRANSPORTATION WARNING Determine the route for transporting the machine by taking into account the width, height and weight of the machine. Obey all state and local laws governing the weight, width and length of a load. Observe all regulations governing wide loads. 13.5 REMOVING AND INSTALLATION OF CANOPY WARNING...
  • Page 96 13. TRANSPORTATION 13. TRANSPORTATION INSTALLATION 1. Install pole 1 with 8 bolts 2 and 8 washers. Tightening torque: 59 to 74 N•m (6 to 7.5 kgf•m) Pole weight: 9 kg (18 lb) 2. Install roof 4 with 4 bolts 5 and 4 washers. Tightening torque: 59 to 74 N•m (6 to 7.5 kgf•m) Roof weight: 15 kg (30 lb)

  • Page 97: Cold Weather Operation

    14. COLD WEATHER OPERATION 14.1 PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows. 14.1.1 FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see “20.
  • Page 98 14. COLD WEATHER OPERATION 14. COLD WEATHER OPERATION 14.1.3 BATTERY WARNING ‡ To avoid gas explosions, do not bring fire or sparks near the battery. ‡ Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor.

  • Page 99: Precautions After Completion Of Work

    14. COLD WEATHER OPERATION 14. COLD WEATHER OPERATION 14.2 PRECAUTIONS AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions. ‡...

  • Page 100: Long-Term Storage

    15.3 AFTER STORAGE NOTICE If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service. Carry out the following procedure when taking the machine out of long-term storage. ‡...

  • Page 101: Troubleshooting

    16. TROUBLESHOOTING 16.1 WHEN MACHINE RUNS OUT OF FUEL WARNING The engine will start, so check carefully that the area around the engine is safe before cranking the engine. If the machine has run out of fuel, add fuel and then bleed the air from the fuel system before starting the engine.

  • Page 102: Towing The Machine

    The machine must not be towed for long distances. ‡ For details of the procedure for towing a machine when it has broken down, please contact your Komatsu distributor. This machine must not be towed except in emergencies. When towing the machine, take the following precautions.
  • Page 103 16. TROUBLESHOOTING 16. TROUBLESHOOTING ‡ Keep the angle of the tow rope as small as possible. Keep the angle between the center lines of the two machines to within 30°. ‡ If the machine is moved suddenly, an excessive load will be applied to the tow rope or bar, and it may break.
  • Page 104 fi When short circuiting main HST circuit In this case, it is always necessary to readjust the high pressure safety valve, so please contact your Komatsu dis- tributor. (1) Remove the floor mat and plate, and check the location of the 2 HST pump high-pressure safety valves.

  • Page 105: If Battery Is Discharged

    16. TROUBLESHOOTING 16. TROUBLESHOOTING 16.3 IF BATTERY IS DISCHARGED WARNING ‡ When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position before starting. ‡ Before starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the battery.
  • Page 106 16. TROUBLESHOOTING 16. TROUBLESHOOTING 16.3.2 PRECAUTIONS FOR CHARGING BATTERY CHARGING BATTERY WHEN MOUNTED ON MACHINE ‡ Before charging, disconnect the cable from the negative . terminal of the battery. Otherwise, an unusually high voltage will damage the alternator. ‡ While charging the battery, remove all battery plugs for satisfac- tory ventilation.
  • Page 107 16. TROUBLESHOOTING 16. TROUBLESHOOTING 16.3.3 STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING INCORRECT ‡ When connecting the cables, never contact the positive + and negative .
  • Page 108 16. TROUBLESHOOTING 16. TROUBLESHOOTING Connecting the booster cables Keep the starting switch at the OFF position. Connect the booster cable as follows, in the order of the num- bers marked in the diagram. 1. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position.

  • Page 109: Other Trouble

    16.4 OTHER TROUBLE 16.4.1 ELECTRICAL SYSTEM ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even ‡...
  • Page 110 16. TROUBLESHOOTING 16.4.2 CHASSIS ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine is running but machine ‡...
  • Page 111 16. TROUBLESHOOTING 16. TROUBLESHOOTING CHASSIS continued (16.4.2) Problem Main causes Remedy Wet type disc brake Brake is not applied when pedal is ‡ Brake linkage disconnected ‡ Connect linkage (check brake depressed control) ‡ Disc has reached wear limit (‡ Replace disc) Brake drags or remains applied ‡...
  • Page 112 16. TROUBLESHOOTING 16.4.3 ENGINE ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure caution pilot ‡...
  • Page 113 16. TROUBLESHOOTING 16. TROUBLESHOOTING ENGINE continued (16.4.3) Problem Main causes Remedy Exhaust gas occasionally turns ‡ Clogged air cleaner element ‡ Clean or replace, see WHEN black REQUIRED ‡ Defective nozzle (‡ Replace nozzle) ‡ Defective compression (‡ See defective compression above) Combustion noise occasionally ‡...

  • Page 114: Maintenance

    MAINTENANCE...

  • Page 115: Guides To Maintenance

    Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu genuine oils: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Always use clean washer fluid: Use automobile window washer fluid and be careful not to let any dirt get into it.
  • Page 116 Checking foreign materials in drained oil and on filters: After oil is changed or filters are replaced, check the oil and filters for metallic particles and foreign materials. If large quantities of metallic particles or foreign materials are found, consult your Komatsu distributor.
  • Page 117 17. GUIDES TO MAINTENANCE 17. GUIDES TO MAINTENANCE Checking undercarriage: When working in rocky areas, check for damage to the undercarriage and for looseness, flaws, wear and damage in bolts and nuts. Precautions when washing machine: ‡ Never spray steam or water directly at the radiator. ‡...

  • Page 118: Outlines Of Service

    When changing the oil, always replace the related filters at the same time. ‡ We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor.
  • Page 119 When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual. ‡ Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system.
  • Page 120 ‡ When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, please contact your Komatsu distributor. ‡ Do not open packs of spare filters until just before they are to be used.

  • Page 121: Outline Of Electric System

    Never remove or disassemble any electric components installed in the machine. ‡ Never install any electric components other than those specified by Komatsu. ‡ Be careful to keep the electric system free of water when washing the machine or when it rains.

  • Page 122: Wear Parts List

    The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book.

  • Page 123: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature

    Water – Add antifreeze 1.21 UK gal WA40,50: 5.8 ¬ 1.53 US gal 1.28 UK gal ª ASTM D975 No. 1 When operating the machine at temperatures below –20°C, other equipment is needed, so please consult your Komatsu distributor. 3-10...
  • Page 124 ‡ We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. Specified capacity: Total amount of oil including oil for components and oil in piping.
  • Page 125 (The 15W40 oil SAE80, 90, 140 NLGI No. 2 Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT (Winter, one EO15-40CD season type) Diesel sigma S Super dieselmulti- AGIP Rotra MP GR MU/EP –...
  • Page 126 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Engine Oil Anti-freeze [CD or CE] Coolant SAE10W, 30, 40 Gear Oil Grease Supplier [Ethylene Glycol 10W30, 15W40 [GL-4 or GL-5] [Lithium-Base] Base] (The 15W40 oil SAE80, 90, 140 NLGI No.

  • Page 127: Standard Tightening Torques For Bolts And Nuts

    (WA20, 30, 40) For greasing work Grease pump 07952-70004 (WA50) Grease cartridge 21R-98-11120 (WA20, 30, 40) (Lithium-base grease: 400 g) Grease cartridge 07950-90403 (WA50) If any of the above tools are broken, please order them from your Komatsu distributor. 3-14...
  • Page 128 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS INSTALLATION OF GREASE PUMP (WA50 ONLY) To install the grease pump to the holder on the floor surface, do as follows. When installing the tools to the machine also, install between the holder, then fit the grease pump to the holder.

  • Page 129: Torque List

    The tightening torque is determined by the width across the flats b of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

  • Page 130: Periodic Replacement Of Safety Critical Parts

    If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the safety critical parts. 3-17...
  • Page 131 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS (WA20) Safety critical parts for periodic replacement Q’ty Replacement interval Fuel hose (fuel tank - feed pump) Fuel hose (feed pump - fuel filter) Fuel hose (fuel filter - injection pump) Fuel return hose (injection pump - fuel filter) Every 2 years or Fuel return hose (fuel filter - fuel tank)
  • Page 132 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 3-19...
  • Page 133 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS (WA30, WA50) Safety critical parts for periodic replacement Q’ty Replacement interval Fuel hose (fuel tank - water separator) Fuel hose (water separator - feed pump) Fuel hose (feed pump - fuel filter) Fuel hose (fuel filter - injection pump) Fuel return hose (injection pump - fuel filter) Every 2 years or...
  • Page 134 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 3-21...
  • Page 135 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS (WA40) Safety critical parts for periodic replacement Q’ty Replacement interval Fuel hose (fuel tank - water separator) Fuel hose (water separator - feed pump) Fuel hose (feed pump - fuel filter) Fuel hose (fuel filter - injection pump) Fuel return hose (injection pump - fuel filter) Every 2 years or...
  • Page 136 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 3-23...

  • Page 137: Maintenance Schedule Chart

    23. MAINTENANCE SCHEDULE CHART 23.1 MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE INITIAL 250 HOURS SERVICE (only after the first 250 hours) Change oil in engine oil pan, replace engine oil filter cartridge 3-27 Replace hydraulic tank filter element and HST filter element 3-27 Check engine valve clearance, adjust 3-27...
  • Page 138 23. MAINTENANCE SCHEDULE CHART 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE Check electric wiring 3-46 Check sound of horn 3-46 Check flashing of lamps, check for dirt or damage 3-47 Check engine exhaust color and sound 3-47 Check operation of gauges 3-47 Check direction of rear view mirror, check for dirt or damage 3-47...

  • Page 139: Maintenance Schedule Chart

    23. MAINTENANCE SCHEDULE CHART 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE EVERY 1000 HOURS SERVICE Change oil in hydraulic tank, replace hydraulic oil filter cartridge and HST filter element 3-57 Lubricating 3-59 ‡ Front drive shaft (3 points) 3-59 ‡ Rear drive shaft (2 points) 3-59 ‡...

  • Page 140: Service Procedure

    24. SERVICE PROCEDURE 24.1 INITIAL 250 HOURS SERVICE Carry out the following maintenance only after the first 250 hours. ‡ CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ‡ REPLACE HYDRAULIC TANK FILTER ELEMENT AND HST FILTER ELEMENT ‡...

  • Page 141: When Required

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.2 WHEN REQUIRED 24.2.1 REPLACE AIR CLEANER ELEMENT WARNING ‡ Never clean or replace the air cleaner element with the engine running. ‡ When using pressure air to clean the element wear safety glasses or goggles to protect the eyes. 1.

  • Page 142: Clean Inside Of Cooling System

    If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol. ‡ In areas where the water is hard, always add Komatsu genuine corrosion resistor agent KI. One packet of corrosion resistor agent contains 100g. The standard density of the mixture should be 7g/¬.
  • Page 143 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE ‡ When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing rate table given below. It is actually better to estimate a temperature about 10˚C lower when deciding the mixing rate.
  • Page 144 Antifreeze is flammable, so keep it away from any flame. ‡ Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. ‡ We recommend use of an antifreeze density gauge to control the mixing proportions.
  • Page 145 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 1. Stop the engine and remove radiator cap 1 slowly. 2. Prepare a container to catch the coolant, then open drain valve 2 at the radiator left lower portion and drain plug 3 at the side of the cylinder block to drain the coolant.

  • Page 146: Drain Water And Sediment From Fuel Tank

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.2.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK 1. Drain before operate the machine. 2. Prepare a container to catch fuel. 3. Open drain valve 1 at fuel tank lower portion, and then drain water and sediment.

  • Page 147: Check Transfer Case Oil Level, Add Oil

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.2.5 CHECK TRANSFER CASE OIL LEVEL, ADD OIL WARNING ‡ When checking the oil level, apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ The oil is at high temperature after the machine has been operated.

  • Page 148: Check Axle Oil Level, Add Oil

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.2.6 CHECK AXLE OIL LEVEL, ADD OIL WARNING ‡ When checking the oil level, apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ The oil is at high temperature after the machine has been operated.

  • Page 149: Clean Transfer Case Breather

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.2.7 CLEAN TRANSFER CASE BREATHER WARNING When cleaning, apply the parking brake, and lock the front and rear frames with the safety bar and pin. Remove all mud and dirt from around the breather with a brush. 1.

  • Page 150: Clean Radiator Fin

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.2.9 CLEAN RADIATOR FINS Carry out this procedure if there is any mud or dirt seen stuck to the radiator. 1. Use compressed air to clean the mud dust, and leaves from the radiator fins. Steam or water may be used instead of com- pressed air.

  • Page 151: Replace Bolt-On Cutting Edge (Option For Wa20)

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.2.10 REPLACE BOLT-ON CUTTING EDGE (option for WA20) WARNING It is extremely dangerous if the work equipment moves when carrying out the turning or replacement operation. Set the work equipment in a stable position, stop the engine, then set the safety lock for the work equipment control lever securely to the LOCK position.

  • Page 152: Adjust Parking Brake

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.2.11 ADJUSTING PARKING BRAKE Checking The standard travel of the parking brake when it is depressed is 4 – 7 notches. If the travel is not within the standard range, adjust as follows. Adjusting WARNING Before carrying out adjustment, always block the tires and take action to prevent the machine from slipping.

  • Page 153: Adjust Parking Brake Release Lever

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.2.12 ADJUST PARKING BRAKE RELEASE LEVER Checking Depress the parking brake pedal 3 – 4 notches, then pull the release lever to return the parking brake pedal to its original position. If the travel is not 35 – 50 mm (1.4 – 2 in) when the lever is released, adjust as follows.

  • Page 154: Adjust Brake Pedal Stroke

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.2.13 ADJUST BRAKE PEDAL STROKE Checking The travel at the tip of the pedal should be 60 – 85 mm (2.4 – 3.4 in). If the travel is not within the standard range, adjust as follows. Adjusting WARNING Before carrying out adjustment, always block the tires and take...

  • Page 155: Check Before Starting

    1. Turn the key in starting switch to the ON position. 2. When each pilot lamp 1 lights on, bulbs are no problem. 3. When each lamp doesn’t light, contact your Komatsu distributor for service. The preheating pilot lamp lights up only when the starting switch is at the HEAT position;...

  • Page 156: Check Fuel Level, Add Fuel

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.3.3 CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If spilling fuel, thoroughly clean up any spillage. 1. Turn the engine starting switch to the ON position, then check the fuel level with fuel gauge G.

  • Page 157: Check Oil Level In Engine Oil Pan, Add Oil

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.3.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the tilt hood at the rear of the machine. 2. Remove dipstick G and wipe the oil off with a cloth. 3. Insert dipstick G fully in the oil filler pipe, then take it out again. 4.

  • Page 158: Check Parking Brake Alarm Buzzer

    The play at the outside circumference of the steering wheel should be 20 – 40 mm (0.8 – 1.6 in). If it is more than 40 mm (1.6 in) or the operation of the steering is not smooth, please contact your Komatsu distributor for inspec- tion. 3-45...

  • Page 159: Check Electric Wiring

    When carrying out walk-around checks or checks before starting, always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of the cause. 24.3.11 CHECK SOUND OF HORN 1.

  • Page 160: Check Flashing Of Lamps, Check For Dirt Or Damage

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.3.12 CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE Check for lamps lighting. 1. Turn the starting switch 1 to ON. 2. Check for the function of lamp switch 2 at A, B and C positions.

  • Page 161: Every 50 Hours Service

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.4 EVERY 50 HOURS SERVICE 24.4.1 CHECK TIRE INFLATION PRESSURE Measure the inflation pressure before operations when the tires are cool. Standard tire inflation pressure: WA20, 40, 50 0.18 MPa (1.8 kgf/cm WA30 0.2 MPa (2.0 kgf/cm NOTICE The appropriate tire inflation pressure differs according to the type of work, so see “12.17 HANDLING THE TIRES”.

  • Page 162: Every 250 Hours Service

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.5 EVERY 250 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. 24.5.1 LUBRICATING WARNING ‡ Apply the parking brake, and lock the front and rear frames with the safety bar and pin.

  • Page 163: Check Oil Level In Hydraulic Tank, Add Oil

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.5.2 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING When the oil filler cap is removed, oil may spurt out, so stop the engine and wait for the oil temperature to go down, then turn the cap slowly to release the internal pressure before removing the cap.

  • Page 164: Check And Clean Air Cleaner Element

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.5.3 CHECK AND CLEAN AIR CLEANER ELEMENT WARNING ‡ Never clean or replace the air cleaner element with the engine running. ‡ When using pressure air to clean the element wear safety glasses or goggles to protect the eyes. Cleaning 1.

  • Page 165: Check Tension Of Fan Belt, Adjust

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.5.4 CHECK TENSION OF FAN BELT, ADJUST CHECKING The deflection of the belt should be approx. 10 to 15 mm (0.4 to 0.6 in) when pressed with a finger force of approx. 59 N (6 kgf) (13 lb) at a point midway between the fan pulley and the alternator pulley.

  • Page 166: Check Battery Electrolyte Level

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.5.5 CHECK BATTERY ELECTROLYTE LEVEL WARNING ‡ To avoid gas explosions, do not bring fire or sparks near the battery. ‡ Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor.

  • Page 167: Every 500 Hours Service

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.6 EVERY 500 HOURS SERVICE Maintenance for every 50 and 250 hours should be carried out at the same time. 24.6.1 REPLACE FUEL FILTER ELEMENT WARNING ‡ Engine is at high temperature immediately after the machine has been operated.

  • Page 168: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge

    4. Loosen drain plug P, and drain the oil. 5. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 6. Install drain plug P. 7. Using the filter wrench, turn filter cartridge 1 counterclockwise to remove it.

  • Page 169: Grease Rear Axle Pivot Pin (2 Points)

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 9. When installing, bring the seal surface into contact with the filter holder, then tighten a further 1/2 to 3/4 turns. 10. After replacing the filter cartridge, add engine oil through oil filler F until the oil level is between the H and L marks on the dipstick.

  • Page 170: Every 1000 Hours Service

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.7 EVERY 1000 HOURS SERVICE Maintenance for every 50, 250 and 500 hours service should be carried out at the same time. 24.7.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER CARTRIDGE AND HST FILTER ELEMENT WARNING The oil is at high temperature immediately after the machine...
  • Page 171 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 8. When installing, bring the parking surface into contact with the seal surface of the filter holder, then tighten 3/4 – 1 turn. 9. Using a wrench, turn HST oil filter case 2 to the left to remove 10.
  • Page 172 24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.7.2 LUBRICATING WARNING ‡ Apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.

  • Page 173: Every 2000 Hours Service

    24. SERVICE PROCEDURE 24. SERVICE PROCEDURE 24.8 EVERY 2000 HOURS SERVICE Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time. 24.8.1 CHANGE OIL IN TRANSFER CASE WARNING The oil is at high temperature after the machine has been operated.
  • Page 174 24.8.3 CHECK ALTERNATOR, STARTING MOTOR The brush may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
  • Page 175 MEMO 3-62...

  • Page 176: Specifications

    SPECIFICATIONS...
  • Page 177 ‡ Operating weight Including 1 operator 1,885 kg (3,770 lb) (55 kg, 110 lb) and a cab ENGINE ‡ Model Komatsu 3D78AE-3A diesel engine ‡ Flywheel horsepower 16.2 kW/2,600 rpm ‡ Max. torque 73.5 N•m/1,500rpm (7.5 kgf•m/1,500 rpm) ‡ Starting motor 12 V 1.8 kW...

  • Page 178: Options, Attachments

    OPTIONS, ATTACHMENTS...

  • Page 179: Optional Parts And Attachments

    fi fi fi Multi coupler for other work equipment fi fi fi fi Steel cab fi fi fi fi Heater Heating operator’s cab : Available in the future The other attachments are also available, so please contact your Komatsu distributor.

  • Page 180: Seat Belt

    27. SEAT BELT Always install a seat belt on machines equipped with ROPS. WARNING ‡ Before fitting the seat belt, check that there is no abnormality in the mounting bracket and mounting belt of the belt. If the belt is worn or damaged, replace it. ‡...

  • Page 181: Adjust Belt Length

    27. SEAT BELT 27. SEAT BELT 27.2 ADJUST BELT LENGTH TO MAKE BELT SHORTER Pull the free end of the belt at the buckle end or tongue end. AE061720 TO MAKE BELT LONGER Set the belt holding the buckle or tongue end at right angles to the buckle or tongue, and pull.

  • Page 182: Equipment With Cab

    28. EQUIPMENT WITH CAB 28.1 SWITCHES 1. ROOM LAMP SWITCH ON: Lights up OFF: Goes off AD051820...
  • Page 183 28. EQUIPMENT WITH CAB 28. EQUIPMENT WITH CAB 2. FRONT WIPER SWITCH This switch operates the front wiper. It also acts as the window washer switch. Operate the switch as follows. ‡ Window washer only Turn the switch to the right to spray out water. ‡...
  • Page 184 28. EQUIPMENT WITH CAB 28. EQUIPMENT WITH CAB 3. REAR WIPER SWITCH This switch operates the rear wiper. It also acts as the window washer switch. Operate the switch as follows. ‡ Window washer only Press the switch to the OFF position to spray out water. AD051850 ‡...
  • Page 185 28. EQUIPMENT WITH CAB 28. EQUIPMENT WITH CAB 4. FRONT WORKING LAMP SWITCH WARNING Always turn the working lamp off before traveling on public roads. The front working lamp lights on when pushing this switch to AD051870 5. REAR WORKING LAMP SWITCH (OPTION FOR MACHINE WITH CAB) WARNING Always turn the working lamp off before traveling on public...

  • Page 186: Rear Window

    28. EQUIPMENT WITH CAB 28. EQUIPMENT WITH CAB ACCELERATOR PEDAL STOPPER LEVER WARNING When carrying out the warming-up operation, always apply the parking brake, set the directional lever to the N position and the work equipment control lever to the HOLD position, and lock with the safety lock.

  • Page 187: Check And Maintenance

    28. EQUIPMENT WITH CAB 28. EQUIPMENT WITH CAB 28.3 CHECK AND MAINTENANCE 28.3.1 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID Check the level of the window washer fluid in tank 1. If the level is low, add automobile washer fluid. Be careful not to let dust get in when filling the tank.
  • Page 188 25. SPECIFICATIONS 25. SPECIFICATIONS...
  • Page 189 ‡ Operating weight Including 1 operator 2,705 kg (5,410 lb) (55 kg, 110 lb) and a cab ENGINE ‡ Model Komatsu 3D84E-3D diesel engine ‡ Flywheel horsepower 21.3 kW/2,500 rpm ‡ Max. torque 90 N•m/1,600pm (9.2 kgf•m/1,600 rpm) ‡ Starting motor 12 V 2 kW ‡...
  • Page 190 25. SPECIFICATIONS 25. SPECIFICATIONS...
  • Page 191 ‡ Operating weight Including 1 operator 3,205 kg (6,410 lb) (55 kg, 110 lb) and a cab ENGINE ‡ Model Komatsu S3D84E-3B diesel engine ‡ Flywheel horsepower 27.2 kW/2,500 rpm ‡ Max. torque 123 N•m/1,600 rpm (12.5 kgf•m/1,600 rpm) ‡ Starting motor 12 V 2 kW ‡...
  • Page 192 25. SPECIFICATIONS 25. SPECIFICATIONS...
  • Page 193 ‡ Operating weight Including 1 operator 3,605 kg (7210 lb) (55 kg, 110 lb) and a cab ENGINE ‡ Model Komatsu S3D84E-3B diesel engine ‡ Flywheel horsepower 27.2 kW/2,500 rpm ‡ Max. torque 123 N•m/1,600 rpm (12.5 kgf•m/1,600 rpm) ‡ Starting motor 12 V 2 kW ‡...
  • Page 194 25. SPECIFICATIONS 25. SPECIFICATIONS...
  • Page 195 MEMO 4-10...

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