Page 1 Operation & EEAM026100 Maintenance Manual WA800 -3E0 WA900 -3E0 WHEEL LOADER SERIAL NUMBER WA800-3E0 - 70001 and up WA900-3E0 - 60001 and up WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
Page 3 FOREWORD...
Page 4 If you sell the machine, be sure to give this manual to the new owners together with the machine. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
Page 5: Foreword
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa- tions.
Page 6 In addition, the illustrations in this manual may show the machine with optional equipment installed. If there are any unclear points or you have any questions, please contact your Komatsu distributor. The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))
Page 7: Noise Emission Levels
FOREWORD SAFETY INFORMATION NOISE EMISSION LEVELS WA800-3E0 q Sound pressure level at the operator’s station, measured according to ISO6394 (Static test method, simulated work- ing cycle). WA900-3E0 q Sound pressure level at the operator’s station, measured according to ISO6394 (Static test method, simulated work- ing cycle).
Page 8: Vibration Levels
FOREWORD SAFETY INFORMATION VIBRATION LEVELS When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera- tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.
Page 9 FOREWORD SAFETY INFORMATION 7. Minimize vibrations for long work cycle or long distance traveling q Reduce speed to prevent bounce q Transport machines long distances between worksites 8. The following guidelines can be effective to minimize risks of low back pain q Operate the machine only when you are in good health.
Page 10: Introduction
FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: q Digging work q Smoothing q Pushing work q Loading work For details of the operating procedure, see “WORK POSSIBLE USING WHEEL LOADER (3-104)“.
Page 11: Visibility From Operator's Seat
FOREWORD INTRODUCTION VISIBILITY FROM OPERATOR'S SEAT The visibility standards (ISO 5006) for this machine require a view shown in the diagram below. VISIBILITY IN IMMEDIATE AREA The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown in the diagram below.
Page 12: 12-M Radius Visibility
FOREWORD INTRODUCTION 12-M RADIUS VISIBILITY The visibility at a radius of 12 m from the machine is as shown in the diagram below. The hatched areas (B) show the areas where the view is blocked when mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot be seen when operating the machine.
Page 13: Necessary Information
FOREWORD NECESSARY INFORMATION NECESSARY INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE On the center right of the front frame. The design of the nameplate differs according to the territory.
Page 14: Position Of Service Meter
POSITION OF SERVICE METER On the lower right of maintenance monitor. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product Identification Number Manufacturers name: KOMATSU LTD. Address: 3-6 Akasaka Minato-ku, 101 Tokyo Japan Distributor Address...
Page 15: Machine Serial Number Plate
FOREWORD NECESSARY INFORMATION MACHINE SERIAL NUMBER PLATE Model Serial Number Manufacturing year Weight Engine power Product Identification Number Manufacturer 1-13...
Page 16: Table Of Contents
CONTENTS CONTENTS FOREWORD FOREWORD ................................. 1-2 SAFETY INFORMATION............................1-3 NOISE EMISSION LEVELS........................1-5 VIBRATION LEVELS ..........................1-6 INTRODUCTION..............................1-8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE ............... 1-8 VISIBILITY FROM OPERATOR'S SEAT ....................1-9 VISIBILITY IN IMMEDIATE AREA..................... 1-9 12-M RADIUS VISIBILITY ....................... 1-10 NECESSARY INFORMATION ...........................
Page 17 CONTENTS GENERAL VIEW OF MACHINE ......................... 3-2 GENERAL VIEW OF CONTROLS AND GAUGES..................3-3 EXPLANATION OF COMPONENTS........................3-6 MACHINE MONITOR ..........................3-6 MONITOR SYSTEM .......................... 3-6 WARNING DISPLAY ......................... 3-9 METER DISPLAY PORTION......................3-15 SWITCHES ............................... 3-22 CONTROL LEVERS, PEDALS ......................... 3-36 MAIN MONITOR TILT LEVER........................
Page 18 CONTENTS ADJUSTMENT..........................3-76 OPERATIONS AND CHECKS BEFORE STARTING ENGINE ............3-81 STARTING ENGINE ..........................3-83 AUTOMATIC WARMING-UP OPERATION..................3-85 OPERATIONS AND CHECKS AFTER STARTING ENGINE ..............3-86 BREAKING-IN THE MACHINE......................3-86 NORMAL OPERATION ........................3-86 STOPPING ENGINE..........................3-88 CHECK AFTER STOPPING ENGINE ...................... 3-88 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE........
Page 19 GUIDES TO MAINTENANCE..........................4-2 OUTLINES OF SERVICE ............................. 4-5 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ............. 4-5 OIL ..............................4-5 FUEL..............................4-6 COOLANT AND WATER FOR DILUTION ..................4-6 GREASE............................4-7 CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ..............4-7 1-17...
Page 20 WEAR PARTS LIST..........................4-10 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................. 4-11 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..... 4-12 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL............................4-14 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..............4-15 TORQUE LIST ............................
Page 21 CONTENTS EVERY 250 HOURS SERVICE ........................ 4-49 CHECK BATTERY ELECTROLYTE LEVEL ................... 4-49 CHECK PARKING BRAKE......................4-50 CHECK ALTERNATOR BELT TENSION, ADJUST ................ 4-51 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST ........4-52 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN ..............4-53 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER .........
Page 22 CONTENTS SPECIFICATIONS SPECIFICATIONS ..............................5-2 ATTACHMENTS, OPTIONS SELECTING BUCKET AND TIRES ........................6-2 HANDLING AUTO-GREASING SYSTEM ......................6-3 METHOD OF OPERATING AUTO-GREASING SYSTEM ................. 6-4 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM............6-4 METHOD OF ADJUSTING DISCHARGE FROM INJECTOR ..............6-11 METHOD OF SETTING TIMER........................ 6-13 METHOD OF CHARGING WITH GREASE ....................
Page 23: Safety
SAFETY WARNING Please be sure that you fully understand this manual and the precautions discribed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precaustions strictly.
Page 24 SAFETY SAFETY SAFETY SAFETY LABELS..............................2-42 LOCATION OF SAFETY LABELS ....................... 2-52 SAFETY LABELS............................2-62 GENERAL PRECAUTIONS SAFETY RULES ............................2-112 IF ABNORMALITIES ARE FOUND......................2-112 CLOTHING AND PERSONAL PROTECTIVE ITEMS ................2-112 FIRE EXTINGUISHER AND FIRST AID KIT ..................... 2-112 SAFETY FEATURES ..........................
Page 25 SAFETY SAFETY STARTING WITH BOOSTER CABLES....................2-302 TOWING ..............................2-312 PRECAUTIONS FOR MAINTENANCE ......................2-322 WARNING TAG ............................2-322 KEEP WORK PLACE CLEAN AND TIDY....................2-322 APPOINT LEADER WHEN WORKING WITH OTHERS ................2-322 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE ..............2-332 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING ..........
Page 26: Safety Labels
If the safety labels are damaged or lost, or cannot be read, replace them with new parts. For details of the part numbers, see this manual or check on the actual part, and order the new part from your Komatsu distributor.
Page 27: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS...
Page 28: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before starting (09651-A0481) q Warning! q Read manual before operation, maintenance, disassembly, assembly and transportation. (2) Caution for lock lever (09654-C0481) q Sign indicates a hazard of unexpected moving of stopped machine. q Lower working device to the ground, move safety lever to lock position and take engine key with you before leaving machine.
Page 29 SAFETY SAFETY LABELS (4) Caution for going close to electric cables (09801-C0481) q Sign indicates an electrocution hazard if machine is brought too near electric power lines. q Keep a safe distance from electric power lines. (5) Do not enter (09162-C0641) q Sign indicates a crush hazard between the articulating parts of the vehicle.
Page 30 SAFETY SAFETY LABELS (7) Caution when coolant is at high temperature (09653-A0641) q Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot. q Allow radiator of hydraulic tank to cool before removing cap.
Page 31 SAFETY SAFETY LABELS (10) “Do not go under work equipment“ sign (09807-C1683) q Sign indicates a crush hazard from falling off of working device. q Keep away when the working device is raised. (11) “Do not open when engine is running“ sign (09667-A0880) q Sign indicates a hazard of rotating parts, such as belt.
Page 32 OR (RECOMMENDED PRACTICES) INTERNATIONAL STANDARD: ISO 3471(ROPS) & ISO 3449 (FOBS) AMERICAN STANDARD: SAEJ q Altering ROPS may weaken it. Consult Komatsu Distributor before altering. q Rops may provide less protection if it has been structurally damaged or involved in roll-over.
Page 33: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES q Only trained and authorized personnel can operate and maintain the machine. q Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. q If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
Page 34 SAFETY GENERAL PRECAUTIONS SAFETY FEATURES q Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. q Understand the method of use of safety features and use them properly. q Never remove any safety features.
Page 35 SAFETY GENERAL PRECAUTIONS ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT q Before standing up from the operator's seat, such as when carrying out adjustment of the operator's seat, or when leaving the machine, always lower the work equipment to the ground, set work equipment lock lever (1) to LOCK position (L), turn parking brake switch (2) ON, set steering lock lever (3) to LOCK position (L), then stop the engine.
Page 36 SAFETY GENERAL PRECAUTIONS q (A) is the emergency escape step. Use this when escaping from the machine in a fire or other emergencies. Do not use it normal situations. q To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps to ensure that you support yourself.
Page 37 SAFETY GENERAL PRECAUTIONS DO NOT GET CAUGHT IN ARTICULATED PORTION q The clearance at the articulated portion changes. If you get caught, it will lead to serious personal injury. Do not allow anyone to enter the articulating range. q The clearance in the area around the work equipment changes according to the movement of the link.
Page 38 SAFETY GENERAL PRECAUTIONS FIRE PREVENTION q Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particu- larly flammable and can be hazardous. To prevent fire, always observe the following: q Do not smoke or use any flame near fuel or oil. q Stop the engine before refueling.
Page 39 If ROPS is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always Komatsu contact your distributor for advice of the method of repair.
Page 40 GENERAL PRECAUTIONS UNAUTHORIZED MODIFICATION If this machine is modified without permission from Komatsu, there is danger that problems may occur with safety and that this may lead to serious personal injury. Modifications may have an adverse effect on items such as machine strength and visibility.
Page 41 SAFETY GENERAL PRECAUTIONS DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows.
Page 42 Do not allow other persons to approach during the opera- tion. q Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2-20...
Page 43: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment con- trol lever, do not start the engine or touch the levers (1). CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. q Remove all dirt from the surface of the window glass to ensure a good view.
Page 44: Operation
SAFETY PRECAUTIONS FOR OPERATION q When starting the engine, sound the horn as a warning. q Do not allow anyone apart from the operator to ride on the machine. q For machines equipped with a back-up alarm, check that the alarm works properly. PRECAUTIONS IN COLD AREAS q Carry out the warming-up operation thoroughly.
Page 45: Precautions When Traveling
This may cause the tires to burst. If a tire bursts, it produces an extremely large destructive force, and this may cause serious injury or accident. If you are going to travel continuously, please consult your Komatsu distributor. 2-23...
Page 46: Traveling On Slopes
SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. q Keep the work equipment at height (A) (70 - 90 cm above the ground) so that it can be lowered immediately to the ground to stop the machine in case of emergency.
Page 47: Prohibited Operations
SAFETY PRECAUTIONS FOR OPERATION PROHIBITED OPERATIONS q It is dangerous to excavate the bottom of a rock face. Never do this. q When digging, never thrust the bucket into a load at an angle. This will bring an excessive load to bear on the machine and will reduce the service life of the machine.
Page 48: Methods Of Using Brake
SAFETY PRECAUTIONS FOR OPERATION q When handling unstable loads, such as round or cylindrical objects, or piled sheets, if the work equipment is raised high, there is danger that the load may fall on top of the operator' compartment and cause serious injury or dam- age.
Page 49: Parking Machine
SAFETY PRECAUTIONS FOR OPERATION PARKING MACHINE q Park the machine on firm, level ground. q Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. q Lower the work equipment completely to the ground. q When leaving the machine, set work equipment lock lever (1) to LOCK position (L), turn parking brake switch (2) ON, set steering lock lever (3) to LOCK position (L), then stop...
Page 50: Transportation
PRECAUTIONS FOR OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 51: Battery
SAFETY PRECAUTIONS FOR OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. q Do not use or charge the battery if the level of the battery electrolyte is below the lower level. This may cause an explosion.
Page 52: Starting With Booster Cables
SAFETY PRECAUTIONS FOR OPERATION STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. q When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the opera- tor's seat and the other working with the battery).
Page 53: Towing
SAFETY PRECAUTIONS FOR OPERATION TOWING WHEN TOWING When towing or being towed, mistakes in the method of selecting and inspecting the wire rope or drawbar, or in the method of towing may lead to serious personal injury. For details of the procedure for towing,see the “METHOD OF TOWING MACHINE (3-145)“ q Always confirm that the wire rope or drawbar used for tow- ing has ample strength for the weight of the machine being towed.
Page 54: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG q Always attach the “DO NOT OPERATE“ warning tag to work equipment control lever (1) in the operator's cab to alert others that you are performing service of maintenance on the machine. Attach additional warning tags around the machine if necessary.
Page 55: Stop Engine Before Carrying Out Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT MAINTENANCE q Stop the machine on firm, level ground. q Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. q Lower the work equipment completely to the ground and stop the engine.
Page 56: Two Workers For Maintenance When Engine Is Running
SAFETY PRECAUTIONS FOR MAINTENANCE q Turn parking brake switch (4) to the ON position, then put blocks under the front and rear of the tires. q Set frame lock bar (5) to LOCK position (L) to lock the front frame and rear frame. TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running.
Page 57: Proper Tools
SAFETY PRECAUTIONS FOR MAINTENANCE q Set work equipment lock lever (1) and steering lock lever (2) to the LOCK position (L) to prevent the work equipment from moving. In addition, turn parking brake switch (3) ON to prevent the machine from moving. q Do not touch any control levers.
Page 58: Accumulator
Do not hit or roll the accumulator, or subject it to any impact. q When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
Page 59: Work Under The Machine
SAFETY PRECAUTIONS FOR MAINTENANCE WORK UNDER THE MACHINE q When carrying out inspection and maintenance with the work equipment raised, use strong support (1) that can fully withstand the weight of the work equipment, and be sure to fix the stands in position securely. NOISE If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
Page 60: Precautions With High-Pressure Oil
If there are any loose hoses or piping, or any leakage of oil or fuel from the hose or piping mount, stop operation and tighten to the specified torque. If any hoses or pipes are damaged or deformed, please contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 61: Waste Materials
SAFETY PRECAUTIONS FOR MAINTENANCE WASTE MATERIALS To prevent pollution, pay careful attention to the method of disposing of waste materials. q Always put oil drained from your machine in containers. Never drain oil directly onto the ground or dump into the sewage system, rivers, the sea, or lakes.
Page 62: Precautions With Tires
To maintain safety, always do as follows. q Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special tech- nology, so always ask your Komatsu distributor to carry out these operations. q Always use the tires specified by Komatsu and maintain the specified inflation pressure.
Page 63: Operation
OPERATION WARNING Please read and make sure that you understand the SAFETY section before reading this section.
Page 64: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Bucket Turn signal lamp Bell crank Rear wheel Bucket cylinder (10) Front wheel Lift arm (11) Lift cylinder Front working lamp (12) Rear working lamp Head lamp (13) Rear combination lamp Side working lamp (14) Rear working lamp...
Page 65: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Step lamp switch (21) Kickdown switch Steering lock lever (22) Hold switch AJSS lever (*) (23) Lift arm control lever Horn switch (24) Bucket control lever Shift down switch (25) Turn signal switch Shift up switch (26) Transmission cut-off switch Directional selector switch...
Page 66 OPERATION GENERAL VIEW...
Page 67 OPERATION GENERAL VIEW Main monitor Maintenance monitor Engine low idling selector switch (16) Fuel gauge Auto-greasing (switch, pilot lamp) (if equipped) (17) Engine water temperature gauge Emergency steering pilot lamp (if equipped) (18) Torque converter oil temperature gauge Turn signal pilot lamp (19) Air cleaner clogging caution pilot lamp (left, right) Central check lamp (CHECK) (20) Service meter...
Page 68: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MACHINE MONITOR MONITOR SYSTEM Meter display portion...
Page 69 OPERATION EXPLANATION OF COMPONENTS The machine monitor system consists of the main monitor (in front of the operator's seat) maintenance monitor (on the right side of the operator's seat), 1st, 2nd, 3rd speed indicator lamps, engine service monitor, engine warning lamp, and prelube indicator lamp.
Page 70 The transmission shift indicator displays 8. Finally, the buzzer sounds twice intermittently (beep, beep) to show that the monitor check is completed. If any monitor does not light up, there is probably a failure or disconnection. Contact your Komatsu distributor for inspection.
Page 71: Warning Display
OPERATION EXPLANATION OF COMPONENTS WARNING DISPLAY Central check lamp (CHECK) Battery charge caution pilot lamp Central caution lamp (CAUTION) Air cleaner clogging caution pilot lamp (Left, Right) Engine water level caution pilot lamp Engine oil level caution pilot lamp Transmission oil filter pilot lamp Brake oil pressure caution pilot lamp (10) Emergency steering pilot lmap (Red) (if equipped) Engine oil pressure caution pilot lamp...
Page 72 OPERATION EXPLANATION OF COMPONENTS CENTRAL CHECK LAMP (CHECK) WARNING If this monitor flashes, carry out inspection and mainte- nance of the appropriate location as soon as possible. q If any abnormality is found in the CHECK items before starting the engine (engine oil level, engine water level), the monitor lamp for the abnormal location will flash and central check lamp (CHECK) (1) will also flash.
Page 73 OPERATION EXPLANATION OF COMPONENTS ENGINE WATER LEVEL CAUTION PILOT LAMP This lamp (3) warns that the coolant level in the radiator has dropped. When carrying out the checks before starting (starting switch ON, engine stopped): If the level of the coolant in the radiator is low, the caution pilot lamp and central CHECK lamp will flash.
Page 74 OPERATION EXPLANATION OF COMPONENTS BRAKE OIL PRESSURE CAUTION PILOT LAMP This lamp (5) warns the operator that the brake oil pressure has dropped. When carrying out checks before starting: When the engine is stopped, the brake oil pressure circuit is not actuated, so the caution pilot lamp and central CHECK lamp are also off.
Page 75 (red) flashes. (Red) If the pilot lamp does not flash, it indicates that there is an abnormality, so please ask your Komatsu distributor to carry out repairs. Do not operate the machine until the problem has been removed.
Page 76 OPERATION EXPLANATION OF COMPONENTS ENGINE WARNING LAMP This lamp (11) warns the operator that there is an abnormality with the engine. During the check before starting (when the starting switch is at the ON position), this lamp should light up for approx. 2 sec- onds, and then go out.
Page 77: Meter Display Portion
OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION Parking brake pilot lamp (11) Remote positioner LOWER stop display lamp Engine pre-heating pilot lamp (if equipped) Front and side working lamp pilot lamp (12) Remote positioner RAISE set pilot lamp Rear working lamp pilot lamp (if equipped) Transumission cut-off pilot lamp (13) Remote positioner LOWER set pilot lamp...
Page 78 OPERATION EXPLANATION OF COMPONENTS PILOT DISPLAY When the starting switch is ON, the pilot display lights up when the display items are functioning. PARKING BRAKE PILOT LAMP This lamp (1) lights up when the parking brake is applied. ENGINE PRE-HEATING PILOT LAMP This lamp (2) informs the operator of the pre-heating status of the electrical intake air heater.
Page 79 OPERATION EXPLANATION OF COMPONENTS TRANSMISSION CUT-OFF PILOT LAMP This lamp (5) lights up when the transmission cut-off switch is turned to ON. If the monitor lamp is ON and the left brake pedal is depressed, the transmission will be returned to neutral. TURN SIGNAL PILOT LAMP When the turn signal lamp flashes, this lamp (6) also flashes.
Page 80 OPERATION EXPLANATION OF COMPONENTS PRELUBE INDICATOR LAMP (If equipped) This lamp (9) flashes, lights up, or goes out according to the status of the prelube system. Flashes: Prelube is needed Lights up: Prelube now taking place OFF: Prelube completed or prelube not needed For details, see “STARTING ENGINE (3-83)“.
Page 81 OPERATION EXPLANATION OF COMPONENTS REMOTE POSITIONER RAISE SET PILOT LAMP (If equipped) This lamp (12) lights up, flashes, or goes out when the remote positioner RAISE stop position is set or the sensor is adjusted. For details, see “REMOTE POSITIONER (3-101)“. REMOTE POSITIONER LOWER SET PILOT LAMP (If equipped) This lamp (13) lights up, flashes, or goes out when the remote...
Page 82 OPERATION EXPLANATION OF COMPONENTS METERS FUEL GAUGE This meter (15) shows the level of fuel in the fuel tank. E indicates that there is no fuel. F indicates that the tank is full. During operations, the green range should be lighted up. Green If the gauge enters the red range during operations, the central warning lamp (CAUTION) and fuel gauge lamp flash.
Page 83 OPERATION EXPLANATION OF COMPONENTS SPEEDOMETER This meter (19) shows the travel speed of the machine. TRANSMISSION SHIFT INDICATOR This indicator (20) shows the transmission speed range. If the forward-reverse selector switch is at the Neutral position, the indicator displays N. If the forward-reverse selector switch is at the FORWARD or REVERSE position, the transmission speed range number is displayed.
Page 84: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES 3-22...
Page 85 OPERATION EXPLANATION OF COMPONENTS Starting switch (19) Room lamp switch Transmission cut-off switch (20) Parking brake switch Transmission cut-off set switch (21) Engine low idling selector switch Front and side working lamp switch (22) Auto-greasing switch (if equipped) Rear working lamp switch (23) Right power window switch Transmission auto shift/manual selector switch (24) Left power window switch...
Page 86 OPERATION EXPLANATION OF COMPONENTS TRANSMISSION CUT-OFF SWITCH WARNING When starting the machine off up a hill, turn the transmission cut-off switch to the OFF position, depress the brake pedal, then gradually depress the accelerator pedal and release the brake slowly to allow the machine to start off.
Page 87 OPERATION EXPLANATION OF COMPONENTS FRONT AND SIDE WORKING LAMP SWITCH Use this push button switch (4) to turn the front working lamp (A) and side working lamp (B) lamp ON and OFF. When the switch is pressed once, the pilot lamp lights up and the lamp is turned ON;...
Page 88 OPERATION EXPLANATION OF COMPONENTS TRANSMISSION AUTO SHIFT/MANUAL SELECTOR SWITCH Press push button switch (6) to turn the switch ON or OFF. When the switch is pressed once, the pilot lamp lights up and the lamp is turned ON; when the switch is pressed again, the pilot lamp goes out and the lamp is turned OFF.
Page 89 OPERATION EXPLANATION OF COMPONENTS LAMP SWITCH Use this switch (8) to light up head lamps (a), side clearance lamps (b), tail lamps (c) and the instrument panel lighting. Position (A): OFF Position (B): Side clearance lamps, tail lamps, and panel light- ing light up Position (C): head lamps light up in addition to lamps at posi- tion (B)
Page 90 OPERATION EXPLANATION OF COMPONENTS DIRECTIONAL SELECTOR SWITCH Use FNR switch (9) on the head of the joystick steering lever to switch the direction of travel for the transmission. (F) position: FORWARD (N) position: Neutral (R) position: REVERSE Use the shift up and shift down switches on the head of the joy- stick steering lever to select the speed range.
Page 91 OPERATION EXPLANATION OF COMPONENTS HORN BUTTON Press this switch (13) at the head of the AJSS lever to sound the horn. HAZARD LAMP SWITCH WARNING Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for other machine operators.
Page 92 OPERATION EXPLANATION OF COMPONENTS FRONT WIPER SWITCH When rotary switch (E) of this switch (16) is turned, the front wiper will move. If push button (F) is pressed, washer liquid will be sprayed out onto the front glass while the button is being pressed. It is possible to check the position of the switch in display win- dow (G).
Page 93 If the parking brake has been used as an emergency brake when traveling at high speed (near the max- imum speed), contact your Komatsu distributor to have the parking brake checked for any abnormal- ity.
Page 94 OPERATION EXPLANATION OF COMPONENTS AUTO-GREASING SWITCH (If equipped) It is possible to use this switch (22) to actuate the auto greasing system when desired, regardless of the setting of the timer in the auto greasing system. Simply press the switch to actuate the greasing. Release the switch to stop greasing.
Page 95 OPERATION EXPLANATION OF COMPONENTS HOLD SWITCH When holding the speed range in position for the automatic transmission, press switch (25) on the side of the lift arm con- trol lever knob. The speed range displayed on the transmission indicator on the main monitor is then fixed and the HOLD dis- play portion lights up.
Page 96 OPERATION EXPLANATION OF COMPONENTS REMOTE POSITIONER RAISE POSITION SET SWITCH (If equipped) Use this switch (27) to when deciding the stopping position of the lift arm at a height above horizontal. Use this switch also when setting to the sensor adjustment mode. For details, see “REMOTE POSITIONER (3-101)“.
Page 97 OPERATION EXPLANATION OF COMPONENTS MACHINE MONITOR MODE SELECTOR SWITCH 2 This switch (31) is used to switch the function of the character display. When the switch is released, it automatically returns to its origi- nal position. The basic operation is as follows. Position (>): Press here to go on to the next screen, or to move the cursor forward, or to increase the number when entering numerals...
Page 98: Control Levers, Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS, PEDALS Steering lock lever Brake pedal AJSS lever Accelerator pedal Work equipment lock lever AJSS lever front-rear adjustment knob Bucket control lever Right armrest adjustment lever Lift arm control lever (10) Left armrest adjustment lever 3-36...
Page 99 OPERATION EXPLANATION OF COMPONENTS STEERING LOCK LEVER WARNING q Regardless of whether the engine is running or stopped, always set the steering lock lever securely to the LOCK position when standing up from the operator's seat. In particular, when the engine is running, if the AJSS lever is not locked and it is touched by mistake, it may cause serious personal injury.
Page 100 OPERATION EXPLANATION OF COMPONENTS WORK EQUIPMENT LOCK LEVER WARNING q Always set the work equipment lock lever securely to the LOCK position when standing up from the operator's seat. If the work equipment lock lever is not securely in the LOCK condition, and work equipment control lever (A) is touched by mistake, it may cause serious personal injury.
Page 101 OPERATION EXPLANATION OF COMPONENTS LIFT ARM CONTROL LEVER This lever (5) is used to operate the lift arm. Position (A): RAISE When the lever is pulled further from the RAISE position, the lever stops at that position (detent position). When the lift arm reaches the maximum height, the lever returns to the HOLD position.
Page 102 OPERATION EXPLANATION OF COMPONENTS BRAKE PEDAL WARNING q When traveling downhill, always use the right brake pedal, and use the braking force of the engine together with the brake. q Do not use the brake pedal repeatedly more than necessary. If the brake is used too frequently, the brake will overheat.
Page 103 OPERATION EXPLANATION OF COMPONENTS AJSS LEVER FRONT-REAR ADJUSTMENT KNOB WARNING Carry out front-rear of adjustment of the AJSS lever with the machine is stopped. If the machine is moving and the lever is operated (adjusted), it may lead to serious personal injury. Pull up this lever (8).
Page 104: Main Monitor Tilt Lever
OPERATION EXPLANATION OF COMPONENTS It is possible to adjust the angle within range (b) of approx. 7°. MAIN MONITOR TILT LEVER WARNING Stop the machine before adjusting the tilt of the main monitor. If this operation (adjustment) is carried out while the machine is moving, it may lead to a serious accident or personal injury.
Page 105: Cap With Lock
OPERATION EXPLANATION OF COMPONENTS CAP WITH LOCK If the machine is equipped with a cap with lock for the fuel tank filler and hydraulic tank filler, open and close the cap as follows. Use the starting switch key to open and close the cap. METHOD OF OPENING AND CLOSING CAP WITH LOCK TO OPEN THE CAP 1.
Page 106: Frame Lock Bar
OPERATION EXPLANATION OF COMPONENTS FRAME LOCK BAR WARNING If the machine is transported or lifted when the frame lock bar is not locking the frame, the machine may suddenly articulate. If the machine articulates, it may cause serious personal injury to people in the surrounding area. Always lock the frame lock bar when transporting or lifting the machine.
Page 107: Towing Pin
Open If any abnormality occurs and it is necessary to use the fuel stop lever, please contact your Komatsu distributor. When starting the engine again, bleed the air from the fuel cir- Close cuit. For details, see “PROCEDURE FOR BLEEDING AIR (3- 144)“.
Page 108: Cab Door Open Lock
OPERATION EXPLANATION OF COMPONENTS CAB DOOR OPEN LOCK This can be used to hold the door open. Open the door so that tip (2) of the lever is aligned with groove (1) of the lock, then pull down knob (3) as shown in the dia- gram.
Page 109: Dust Indicator
OPERATION EXPLANATION OF COMPONENTS DUST INDICATOR The dust indicator is at the front of the engine hood at the rear of the operator's compartment. The display is given in five stages according to the degree of clogging of the element. If the air cleaner is clogged, the air cleaner clogging caution pilot lamp on the maintenance monitor lights up to inform the operator that the air cleaner needs to be cleaned.
Page 110: Fuse Capacity And Name Of Circuit
OPERATION EXPLANATION OF COMPONENTS FUSE CAPACITY AND NAME OF CIRCUIT FUSE BOX 1 Fuse capacity Name of circuit Main lamp circuit Backup lamp, Brake lamp Turn signal lamp Head lamp (R.H.) Head lamp (L.H.) Side clearance lamp (R.H.) Side clearance lamp (L.H.) Parking brake Rotating lamp (if equipped) (10)
Page 111: Circuit Breaker
OPERATION EXPLANATION OF COMPONENTS CIRCUIT BREAKER NOTICE q When resetting the circuit breaker, always turn the starting switch OFF first. q Do not keep the circuit breaker reset button pressed. If the electric power does not come on when the starting switch is turned ON, the circuit breaker has probably been tripped, so check.
Page 112: Lunch Box Tray
OPERATION EXPLANATION OF COMPONENTS LUNCH BOX TRAY There is a space for a lunch box at the right rear of the cab. Even a large lunch box 35 cm long, 22 cm wide and 18 cm high can be placed easily and fixed with a band. NOTICE The engine service monitor is installed under the lunch- box, so do not place any wireless device on top of the...
Page 113: Location Of Fire Extinguisher
OPERATION EXPLANATION OF COMPONENTS LOCATION OF FIRE EXTINGUISHER (If equipped) Fire extinguisher (1) is on the left side of the ROPS. POWER OUTLET NOTICE q There are two power sources: 12V and 24V Check the voltage of the electrical equipment and select the appropriate power source. Mistaken use, such as using 24V as the power source for 12V equipment, will cause failure of the equipment.
Page 114: Am/Fm Radio-Cassette Stereo
OPERATION EXPLANATION OF COMPONENTS AM/FM RADIO-CASSETTE STEREO (If equipped) EXPLANATION OF COMPONENTS (1) Power switch/volume (8) Cassette door (2) Auto-store/preset scan button (9) Fast forward, rewind buttons (3) Bass control knob (10) Preset buttons (4) Treble control knob (11) Metal tape button (5) Loudness button (12) Manual tuning buttons (6) Time/radio display selector button...
Page 115 OPERATION EXPLANATION OF COMPONENTS POWER SWITCH/VOLUME Turn this knob (1) to the right until it clicks to turn the power on. Turn it further to increase the volume. AUTO-STORE/PRESET SCAN BUTTON Use this button (2) to actuate the preset scan and auto-store functions.
Page 116 OPERATION EXPLANATION OF COMPONENTS TREBLE CONTROL KNOB Turn this button (4) to the left to reduce the low tones; turn it to the right to emphasize the high tones. Direction (a): High tone reduced Direction (b): High tone emphasized LOUDNESS BUTTON This button (5) is used when playing at low volume.
Page 117 OPERATION EXPLANATION OF COMPONENTS TAPE EJECT BUTTON This button (7) is used to stop the tape and to eject the cas- sette. When this button is pressed, the tape is ejected and the radio plays. CASSETTE DOOR Set the cassette with the exposed portion of the tape on the right side and insert it through the cassette door (8).
Page 118 OPERATION EXPLANATION OF COMPONENTS METAL TAPE BUTTON (used also for preset button No. 5) This button (11) is used when playing a metal or chrome tape. This button is also used for preset button No. 5. When it is pressed, “MTL“ appears on the display. MANUAL TUNING BUTTONS These buttons (12) are used for manual tuning.
Page 119: Method Of Operation
OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS To listen to a preset station, use band selector button (1) to select AM, FM1, or FM2, then press the preset switch number to listen to the desired station. It is possible to preset six AM stations and 12 FM stations (FM1: 6, FM2: 6).
Page 120 OPERATION EXPLANATION OF COMPONENTS LISTENING TO RADIO 1. Turn the starting switch ON, then turn power switch (1) ON. 2. Set band selector button (2) to AM or FM. 3. Select the station with the preset buttons or manual tuning button (3).
Page 121: Precautions When Using
If the sound cannot be heard, nothing is displayed, or any other problem occurs, turn off the power switch and ask your Komatsu distributor to make repairs without delay. q Stow the antenna when traveling in places with low overhead clearance.
Page 122: Air Conditioner
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER (If equipped) GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL Fan switch FRESH/RECIRC selector switch Air conditioner switch Temperature control switch Mode selector switch Temperature level indicator lamp FAN SWITCH This switch (1) can be used to adjust the airflow in four stages. It also acts as the main switch for the air conditioner.
Page 123 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH This switch (2) is used to start or stop the cooling or dehumidi- fying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.
Page 124 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH The temperature can be adjusted with this switch (5) by press- ing and holding the up or down button. The temperature level indicator lamps light up to display the temperature of the air coming from the vents. The more the blue lamps light up, the lower the temperature is.
Page 125: Method Of Operation
OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION Switch Air conditioner Temperature FRESH/RECIRC Mode selector Fan switch Condition of use switch control switch selector switch switch Rapid All blue RECIRC FACE Cooling More than half Normal HI - LO FRESH FACE are blue Dehumidifying, More than half...
Page 126: Use Air Conditioner With Care
OPERATION EXPLANATION OF COMPONENTS USE AIR CONDITIONER WITH CARE NOTICE q When running the air conditioner, always start with the engine running at low speed. Never start the air conditioner when the engine is running at high speed. It will cause failure of the air conditioner. q If water gets into the control panel or sunlight sensor, it may lead to unexpected failure, be careful not to let water get on these parts.
Page 127: Handling Wireless
OPERATION EXPLANATION OF COMPONENTS HANDLING WIRELESS NOTICE The engine service monitor is installed under the lunchbox, so do not place any wireless device on top of the lunchbox. METHOD OF INSTALLING WIRELESS When installing the wireless, there is mounting seat (2) under cover (1) at the rear right of the cab. (M10 x 4) There are 30 mm holes at 4 places in the steel plate inside the mounting cover.
Page 128: Operation
Always check thoroughly and repair any problems or contact your Komatsu distributor. q Always repair any damage to the handrails and steps, and tighten any loose bolts. Failure to do this may cause workers to fall and suffer serious personal injury.
Page 129 12. Check for loose bolts on ROPS Check for any loose or damaged bolts. If any loose bolts are found tighten them to 2452 to 3050 Nm (250 to 310 kgm). If any bolts are damaged, replace them with genuine Komatsu bolts. 3-67...
Page 130 OPERATION OPERATION 13. Clean cab window. Clean the cab window to ensure good visibility when oper- ating the machine. When cleaning the front glass, use commercially available cleaning equipment and carry out the cleaning operation from the ground. 14. Check rear view mirror, under view mirror Check that the mirrors are not damaged.
Page 131: Check Before Starting
3 seconds and the alarm buzzer sounds for approx. 1 sec. If the lamps do not light up, there is probably a failure or disconnection. Contact your Komatsu distributor for inspec- tion. CHECK DUST INDICATOR 1.
Page 132 OPERATION OPERATION 2. After cleaning and replacing the element, push the dust indicator button to return the red display to its original posi- tion. DRAIN WATER FROM FUEL PRE-FILTER 1. Check if any water is accumulated in cap (1) at the bottom of the filter.
Page 133 OPERATION OPERATION CHECK COOLANT LEVEL, ADD COOLANT WARNING q Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank. q Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
Page 134 OPERATION OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
Page 135 OPERATION OPERATION CHECK BRAKE OIL TANK LEVEL, ADD OIL CAUTION When adding oil to the brake oil tank, always use the recommended oil given in “USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (4-12)“. 1. Check from the ground that the brake oil level in the brake oil tank on the left side of the machine is within sight gauge (1) installed to the side of the brake tank.
Page 136 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up com- pletely. Never bring flames near fuel because it is highly flammable and dangerous. NOTICE If the engine has stopped after running out of fuel, it is necessary to use the priming pump to bleed all the air from the fuel circuit before starting the engine again.
Page 137 CHECK BRAKE PEDAL Drive the machine forward and check the effect of the brakes. If there is any problem in the actuation of the brakes, please contact your Komatsu distributor to have the brakes adjusted. CHECK INFLATION PRESSURE OF TIRES Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work.
Page 138 If the wall or rubber sheet are damaged or have come off, please contact your Komatsu distributor for repairs.
Page 139 OPERATION OPERATION (A) Fore-and-aft adjustment Move lever (1) up and move the seat to the desired position and release the lever. Fore-and-aft adjustment: 210 mm (10 mm x 21 stages) (B) Adjusting seat angle Move lever (2) up, move the seat cushion at the front up or down to set to the desired position, then release the lever.
Page 140 OPERATION OPERATION When adjusting, do not remove your weight from the seat or change the load in any other way. If this is done, the air may be released from the suspension's seat. (E) Fore-and-aft adjustment of seat cushion Operate lever (4) up, set the seat cushion to the desired position, then release the lever. Fore-and-aft adjustment: 60 mm (F) Adjusting reclining angle Operate lever (5) up and move the back cushion to the front or rear.
Page 141 OPERATION OPERATION (M) Adjusting hardness of suspension damper Operate knob (9) to adjust the damping force of the suspension damper. If knob (9) is moved to face the front of the seat (A), the damping force becomes stronger; if the knob is moved to face the rear of the seat (B), the damping force becomes weaker.
Page 142 OPERATION OPERATION ADJUSTING MIRRORS WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may injure someone seriously. Adjust the position so that the mirror gives a good view from the operator's seat. In particular, be careful to adjust so that it is possible to see people on the left and right sides at the rear of the machine.
Page 143 OPERATION OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING Before starting the engine, check that steering lock lever (3) and work equipment lock lever (5) are securely at the LOCK position. If work equipment control lever (4) or AJSS lever (2) are touched by mistake when the engine starts, the work equipment or machine may move unexpectedly, leading to serious personal injury.
Page 144 When this happens, 88 is displayed on the speedometer, and 8 is displayed on the transmission shift indicator. If the monitor lamps do not light up, there is probably a fail- ure or disconnection, so please contact your Komatsu dis- tributor for inspection. 3-82...
Page 145 OPERATION OPERATION STARTING ENGINE WARNING q Sit down in the operator's seat before starting the engine. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause seri- ous bodily injury or fire. q Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 146 If the prelube is not completed even when it is carried out 3 times, there is probably an abnormality in the prelube system, so contact your Komatsu distributor for inspection and repair. (For details of the method of starting the engine in emergencies, see “PRELUBE SKIP FUNCTION WHEN START- ING IN EMERGENCY (3-153)“.)
Page 147 OPERATION OPERATION q The turbocharger rotates at extremely high speed. Immediately after the engine is started, the pressure of the lubricating oil has not risen sufficiently, so if the engine speed is suddenly raised, it may lead to damage or sei- zure of the turbocharger bearing.
Page 148 BREAKING-IN THE MACHINE CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
Page 149 Run the engine under a light load until the engine water temperature gauge (4) and torque converter oil tempera- ture gauge (5) enter the green range. 5. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3-87...
Page 150 OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Conse- quently, 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 it.
Page 151 OPERATION OPERATION MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE3 WARNING q Always remove the frame lock bar before traveling. If it is not removed, the steering will not work and this may lead to serious personal injury. q When moving the machine off, check that the surrounding area is safe, then sound the horn and start the machine.
Page 152 OPERATION OPERATION 2. Set work equipment lock lever (4) (for bucket control lever (2) and lift arm control lever (3)) and steering lock lever (6) (for AJSS lever (5)) to FREE position (F). REMARK If the steering lock lever is not set to FREE position (F), the directional selector switch will remain at the N position even if the switch is operated.
Page 153 OPERATION OPERATION Auto shift: Transmission auto shift/manual selector pilot lamp goes out The transmission automatically shifts gear according to the travel speed. The maximum speed range selected for automatic transmission is displayed on the 1st, 2nd, 3rd indicator lamps at the bottom of the main monitor. Manual shift: Transmission auto shift/manual selector pilot lamp lights up The machine travels in the speed range is selected by the shift up, shift down switch.
Page 154 OPERATION OPERATION REMARK When moving the machine off on a hill, turn the transmission cut-off switch (14) OFF, depress left brake pedal (15), set direc- tional selector switch (12) to F, then depress the accelerator pedal (3) and gradually release left brake pedal (15) to let the machine move off.
Page 155 OPERATION OPERATION CONTROL WHEN SHIFTING DOWN AT HIGH SPEED Shifting down at high speed has an adverse effect on the durability of the torque converter. Based on the table below, when shifting down at high speed, the alarm buzzer sounds for 3 seconds (repeated short beeps).
Page 156 Position (F): Forward Position (N): Neutral Position (R): Reverse q Check that the backup alarm sounds when the directional selector switch is set to REVERSE. If the backup alarm does not sound, please ask your Komatsu distributor to carry out repairs. 3-94...
Page 157 OPERATION OPERATION CONTROL FOR CHANGE OF TRAVEL DIRECTION AT HIGH SPEED Switching between forward and reverse at high speed has a bad effect on the durability of the transmission. In range (II) shown in the chart below, the alarm buzzer sounds for 3 seconds (rapid intermittent sound), so if it sounds, depress the brake immediately to fully reduce the travel speed, then switch between forward and reverse.
Page 158 OPERATION OPERATION STOPPING THE MACHINE WARNING q Avoid sudden stopping. As far as possible, always leave a margin when stopping the machine. q Avoid parking the machine on a slope. If it is neces- sary to park the machine on a slope, stop the machine facing directly down the slope, fit blocks under the tires and lower the bucket to the ground to prevent the machine from moving.
Page 159 OPERATION OPERATION 3. Push parking brake switch (5) to apply the parking brake. REMARK When the parking brake is applied, the transmission is auto- matically returned to neutral. TRANSMISSION CUT-OFF FUNCTION When the transmission cut-off switch is turned ON, the pilot lamp lights up and the following transmission cut-off function is actuated.
Page 160 OPERATION OPERATION ADJUSTING TRANSMISSION CUT-OFF POSITION CAUTION Apply the parking brake before adjusting the transmission cut-off position. Adjust the depression position of the left brake pedal used to shift the transmission to neutral at the position to match the operation. 1.
Page 161 When making a full turn, operate the AJSS lever to the end of its travel. Do not try to operate it any further. In addition, check that the actuation of the steering is normal. If any abnormality is found, please ask your Komatsu distributor to carry out inspection. 3-99...
Page 162 OPERATION OPERATION OPERATION OF WORK EQUIPMENT WARNING q When standing up from the operator's seat, always set the work equipment lock lever securely to the LOCK position. If the work equipment lock lever is not locked, and work equipment control lever (A) is touched by mistake, this may lead to serious personal injury.
Page 163 OPERATION OPERATION BUCKET CONTROL LEVER Set the work equipment lock lever to the FREE position before operating the control lever. Position (A): TILT Position (B): HOLD The bucket is stopped and held in position. Position (C): DUMP When the bucket control lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position.
Page 164 OPERATION OPERATION 2. When the remote positioner RAISE stop display lamp (2) is lighted up, if the lift arm control lever is moved from HOLD position (A) to RAISE position (B), the lever will stay in that position. When the lift arm rises to the RAISE stop set position, it will reduce speed and stop, and at the same time, the lift arm control lever will return to HOLD position (A).
Page 165 2 again, and check that the condition in Step 3 is correct (the set lamps light up for 2 seconds and then go out). ADJUSTING REMOTE POSITIONER When the lift arm has been removed or the setting does not work efficiently, please contact your Komatsu distribu- tor for adjustment. 3-103...
Page 166 OPERATION OPERATION WORK POSSIBLE USING WHEEL LOADER This section explains about general operations. Be sure to operate the machine correctly. For details, see “PRE- CAUTIONS WHEN HANDLING BLASTED ROCK (3-109)“. In addition to the following, it is possible to further increase the range of applications by using various attachments. DIGGING OPERATIONS WARNING Always set the machine facing directly to the front when carrying out digging or scooping operations.
Page 167 OPERATION OPERATION 2. Shift down immediately in front of the material to be loaded. When completing the shift down, depress the Stockpile accelerator pedal at the same time and thrust the bucket into the material. REMARK To reduce fuel consumption, depress the accelerator pedal the minimum possible amount.
Page 168 OPERATION OPERATION DIGGING AND LOADING ON LEVEL GROUND q 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. This operation should be carried out in 1st gear.
Page 169 OPERATION OPERATION 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 8 degrees. 1.
Page 170 OPERATION OPERATION 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 q Always keep the job site level. When the lift arm is raised with the bucket loaded, it is dangerous to operate the steering suddenly or apply the brakes suddenly.
Page 171 OPERATION OPERATION V-SHAPE LOADING Position the dump truck so that the direction of approach of the wheel loader is approx. 60 degrees from the direction of approach to the stockpile. After loading the bucket, drive the wheel loader in reverse, then turn it to face the dump truck and travel forward to load the dump truck.
Page 172 OPERATION OPERATION SHIFTING TRANSMISSION WHEN THRUSTING BUCKET IN When thrusting the bucket into the facing to carry out excava- tion, do not shift down with the accelerator pedal depressed (with the engine speed raised). If the transmission shifts down when the engine speed is high, there will be an excessive load on the engine, torque converter, transmission, axles, final drive, and the whole power train.
Page 173 OPERATION OPERATION BUCKET DUMP ANGLE WHEN LEVELLING Drive the machine in reverse when carrying out leveling opera- tions. If leveling operations are carried out with the machine traveling forward, do not make angle (a) between the cutting edge of the bucket and the ground surface facing down more than 8°.
Page 174 OPERATION OPERATION BUCKET DUMP OPERATION WHEN DIGGING Do not operate the bucket in the DUMP direction when digging. If the bucket control lever is operated to the DUMP position during digging, the machine will not be able to travel forward, the tires will slip, and an excessive load will be brought to bear on the work equipment.
Page 175 OPERATION OPERATION TREATMENT OF LOOSENED BOULDERS WARNING Do not use this machine to deal with loosened boulders. If the boulder is dropped by mistake when han- dling it, there is danger that it may fall on top of the operator's compartment and cause serious personal injury.
Page 176 OPERATION OPERATION SWITCHING BETWEEN FORWARD AND REVERSE Do not switch the direction of travel of the machine between forward and reverse when traveling at high speed or when the accelerator pedal is depressed. When the machine is traveling at high speed or when the accelerator pedal is depressed, the engine speed is high, and if the direction of travel is switched between forward and reverse.
Page 177 OPERATION OPERATION APPROACHING FACING NOTICE q When approaching the facing and lowering the bucket to the ground, do not drop the bucket suddenly into contact with the ground. If the bucket is dropped suddenly, the bucket, work equipment, area around the pins, and the machine frame will be subjected to excessive shock, and this will lead to damage or deformation of various parts of the machine.
Page 178 OPERATION OPERATION DIGGING NOTICE q Do not shift down with the accelerator pedal depressed (with the engine speed raised). If the transmis- sion is shifted down when the engine speed is high, there will be an excessive load on the engine, torque converter, transmission, axles, final drive, and the whole power train.
Page 179 OPERATION OPERATION TRAVELING IN REVERSE AFTER EXCAVATING NOTICE q Do not operate the steering immediately after starting to travel in reverse. The bucket is still thrust into the rocks, so if the steering is operated, excessive force will be brought to bear on the bucket or frame, and there is danger of damage to the frame.
Page 180 OPERATION OPERATION APPROACHING DUMP TRUCK WARNING Do not operate the steering suddenly when the bucket is raised. If the steering is operated when the bucket is raised, there is danger that the machine may tip over and cause serious personal injury. NOTICE q Do not shift down with the accelerator pedal depressed (with the engine speed raised).
Page 181 OPERATION OPERATION LOADING DUMP TRUCK NOTICE q Do not load the dump truck suddenly from a high position. If the dump truck is loaded like this, the dump truck will suffer impact load and there is danger that this may damage the body. q Do not operate the dump or stop operations when the engine is running at high speed.
Page 182 OPERATION OPERATION REVERSING AWAY FROM DUMP TRUCK NOTICE q Do not shift down with the accelerator pedal depressed (with the engine speed raised). If the transmis- sion is shifted down when the engine speed is high, there will be an excessive load on the engine, torque converter, transmission, axles, final drive, and the whole power train.
Page 183 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.
Page 184 Before driving the machine, carry out the checks before starting. q 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. WA800-3E0 Max.
Page 185 OPERATION OPERATION WA900-3E0 Ambient Max. travel Traveling time breaking time temperature (°C) speed (km/h Travel Break Repeat 13 km or 40’ (3H) Repeat Travel Break 13 km or 35’ (3H) Break Repeat Travel 13 km or 25’ (3H) Travel Repeat Break 13 km or 35’...
Page 186 OPERATION OPERATION ADJUSTING WORK EQUIPMENT POSTURE WARNING q Stop the machine on level ground and put blocks in front of and behind the tires. q Turn the parking brake switch ON. q Lock the front and rear frames with the frame lock bar. q Always hang a warning tag on the work equipment control levers.
Page 187 This method of removal and installation is applicable to the standard specification machine. The method of removal and installation will differ according to the attachments and options that are installed. For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor. 3-125...
Page 188 OPERATION OPERATION REMOVING THE BUCKET 1. Remove mounting bolt (1). 2. Sling the bucket link, then pull out bucket link pin (2). Secure the bucket link to the tilt lever with wires. 3. Remove mounting bolt (3). 4. Pull out and remove bucket hinge pin (4) on both sides of the bucket.
Page 189 OPERATION OPERATION 5. Disconnect the lift arm and bucket. Bucket link Lift arm Bucket INSTALLING THE BUCKET Before installing the bucket, remove all grease, mud, or sand and clean the pin, pin hole, and area around the boss. (If there is any rust or dirt on the inside surface of the pin hole, use sandpaper and remove it carefully.) After cleaning, coat the pin and inside surface of the pin hole with fresh grease.
Page 190 Assemble a pin that has no grease hole at the bucket link. 9. Coat the bucket hinge pin and bucket link pin with grease. For details, see “LUBRICATING (4-45)“. For details of removing and installing the bucket, please contact your Komatsu distributor. 3-128...
Page 191 OPERATION OPERATION PARKING MACHINE WARNING q Avoid sudden stopping. As far as possible, always leave a margin when stopping the machine. q Avoid parking the machine on a slope. If it is neces- sary to park the machine on a slope, stop the machine facing directly down the slope, fit blocks under the tires and lower the bucket to the ground to prevent the machine from moving.
Page 192 OPERATION OPERATION 2. Set directional selector switch (3) to the N position. 3. Turn parking brake switch (4) ON to apply the parking brake. NOTICE When the parking brake is applied, the transmission is automatically returned to neutral. 4. Operate lift arm control lever (5) to lower the bucket to the ground.
Page 193 OPERATION OPERATION CHECKS AFTER COMPLETION OF OPERATION Check the engine water temperature, engine oil pressure, torque converter oil temperature, and fuel level with the machine monitor. If the engine has overheated, do not stop it suddenly. Run the engine at a midrange speed to allow the engine to cool down before stopping it.
Page 194 When the bead is damaged For tubeless tires, when there is air leakage or improper repair Bead Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. TIRE PRESSURE Measure the tire pressure before starting operations, when the tires are cool.
Page 195 OPERATION OPERATION q For operations on normal road surfaces, rock digging operations: High end of range in air pressure chart q Stockpile operations on soft ground: Average pressure in air pressure chart q Operations on sand (operations not using much digging force): Low end of range in air pressure chart If the deflection of the tire is excessive, raise the inflation pressure within the limits given in the table to give a suit- able deflection (see deflection ratio).
Page 196 When traveling continuously with load and carry operations, choose the correct tires to match the operating condi- tions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged, so con- tact your Komatsu distributor or tire dealer when selecting tires. 3-134...
Page 197 LOADING, UNLOADING WORK WARNING When transporting this machine, observe all related laws and regulations. Disassembling for transporta- tion is needed. Consult your Komatsu distributor for transporting the machine. METHOD OF SECURING MACHINE Load the machine onto a trailer as follows: 1.
Page 198 OPERATION TRANSPORTATION 4. Turn the parking brake switch to the ON position to apply the parking brake. 5. Turn the starting switch to the OFF position to stop the engine, and pull out the starting switch key. 6. Set the frame lock bar to LOCK position (L) to prevent the front frame and rear frame from articulating.
Page 199 Use protectors to prevent the wire rope from being cut on sharp corners and to prevent the wire rope from cutting into the machine bodywork. q When using a spreader bar, select an ample width to prevent contact with the machine. Please consult your Komatsu distributor before carrying out lifting work. 3-137...
Page 200 OPERATION TRANSPORTATION LOCATION OF LIFTING POSITION MARK WEIGHT TABLE Center of gravity Operating weight Front wheel load Rear wheel load (from front axle) WA800-3E0 101825 kg 58935 kg 42890 kg 2300 mm WA900-3E0 107125 kg 59735 kg 47390 kg 2410 mm LIFTING PROCEDURE The machine can be lifted only if it has hook mark labels.
Page 201 OPERATION TRANSPORTATION 2. Set the work equipment lock lever for the work equipment control lever to LOCK position (L). 3. Set the steering lock lever to LOCK position (L). 4. Stop the engine, check that the area around the operator's compartment is safe, then set the frame lock bar to the LOCK position (L) to prevent the front frame and rear frame from articulating.
Page 202 Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze. NOTICE q If it is available, always use Komatsu super coolant (AF-NAC). If it is not available, use permanent type coolant. q Never use methanol, ethanol, or propanol-based antifreeze.
Page 203 OPERATION COLD WEATHER OPERATION BATTERY WARNING q The battery generates flammable gas. Do not bring fire or sparks near the battery. q Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 204 AJSS lever is operated. RECOMMENDED OIL Select the oil from the table below according to the ambient temperature. KIND OF Recommended RESERVOIR AMBIENT TEMPERATURE FLUID Komatsu Fluids Hydraulic HO46-HM Hydraulic system HO-MVK 3-142...
Page 205 NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it. q Wipe off the grease from the hydraulic cylinder rods.
Page 206 OPERATION TROUBLESHOOTING TROUBLESHOOTING WHEN MACHINE RUNS OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting the engine. Always watch the fuel level and be careful not to run out of fuel. If the engine has stopped because of lack of fuel, it is necessary to use the priming pump to bleed the air com- pletely from the fuel circuit.
Page 207 This operation is only for towing short distances. Do not tow the machine for long distances. q Please consult your Komatsu distributor for information about towing a disabled machine. This machine must not be towed except in emergencies. When towing the machine, take the following precau- tions.
Page 208 OPERATION TROUBLESHOOTING q Before releasing the brakes, put blocks under the wheels to prevent the machine from moving. If the wheels are not blocked, the machine may suddenly move. q When towing a machine, tow it at a low speed of less than 2 km/h (1.2 MPH), and for a distance of a few meters to a place where repairs can be carried out.
Page 209 OPERATION TROUBLESHOOTING RELEASING PARKING BRAKE Please ask your Komatsu distributor to release the parking brake. WARNING q When releasing the parking brake, stop the machine on level ground and check that the surrounding area is safe. If it is necessary to release the brake on a slope in an emergency, block the tires before starting the operation.
Page 210 EMERGENCY TRAVEL OPERATION The normal gear shifting operation is carried out by electric signals. If there should be a failure in the electrical system and the machine does not move, please contact your Komatsu distributor to have the machine moved. NOTICE Always request your Komatsu distributor to carry out the emergency travel operation.
Page 211 OPERATION TROUBLESHOOTING 3. When installing the battery, connect the ground cable last. Insert the hole of the terminal on the battery and tighten the nut. Tightening torque: 5.9 to 9.8 Nm {0.6 to 1.0 kgm} REMARK There are two batteries each (total: 4) on both sides at the rear of the machine. There is also one battery each for the ground (total: 2) on both sides of the machine.
Page 212 OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows. PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING q When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. q When starting the engine with a booster cable, wear safety glasses and rubber gloves.
Page 213 OPERATION TROUBLESHOOTING STARTING ENGINE WARNING Check that the lock levers (work equipment, steering) and parking brake levers of both the normal machine and the problem machine are at the LOCK position. Check also that all control levers are at the HOLD position.
Page 214 OPERATION TROUBLESHOOTING METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED WARNING If there is some pressure remaining in the accumulator after the engine stops, the work equipment can be lowered. Check that the surrounding area is safe, then lower the work equipment. 1.
Page 215 ON, then ask your Komatsu distributor to carry out repairs. PROCEDURE FOR CONNECTING EMERGENCY START CONNECTOR 1. Inside the right console box around the prelube controller, there are 3-pole connectors (2 each) with tags saying “PRE1“...
Page 216 OPERATION TROUBLESHOOTING 2. When starting the engine without carrying out the prelube operation, remove the two sets of connectors and connect the PRE1 and PRE2 connectors in their place. 3. Turn the key in starting switch (1) to the START position to crank the starting motor without carrying out the prelube operation.
Page 217 TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ): Always contact your Komatsu distributor when dealing with these items. q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even •Defective wiring...
Page 218 OPERATION TROUBLESHOOTING CHASSIS ): Always contact your Komatsu distributor when dealing with these items. q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Transmission •Parking brake is applied •Release parking brake...
Page 219 OPERATION TROUBLESHOOTING Problem Main causes Remedy Hydraulic system Lack of lifting power for bucket •Lack of oil •Add oil to specified level. See EVERY 100 HOURS SERVICE Bucket takes time to rise •Clogged hydraulic tank filter •Replace filter. See EVERY 2000 HOURS SERVICE Excessive bubbles in oil •Low quality oil being used...
Page 220 OPERATION TROUBLESHOOTING ENGINE ): Always contact your Komatsu distributor when dealing with these items. q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy •Engine oil pan oil level is low (sucking •Add oil to specified level, see CHECK...
Page 221 However, if this problem is left without any action being taken, it may lead to serious failure, so after completing the day's operations, ask your Komatsu distributor to carry out inspection and maintenance. ACTION CODE DISPLAY (ENGINE SERVICE MONITOR PORTION)
Page 222 If action codes E01, E02, or E03 are displayed on the character display, stop operations, check the content of the display, and take the following action. E03: When this code is displayed, stop the machine immedi- ately, check the failure code, and contact your Komatsu distrib- utor for repairs. REMARK “E03“...
Page 223 2. Press the top portion (>) of machine monitor mode selector switch 2 (1) again. If there is no other failure, “KOMATSU“ is displayed for several seconds, then the display returns to the action code. If more than one failure has occurred, the next failure code is displayed.
Page 224 OPERATION TROUBLESHOOTING 3-162...
Page 225 MAINTENANCE WARNING Please read and make sure that you understand the SAFETY section before reading this section.
Page 226 Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE OILS: For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID: Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 227 MAINTENANCE GUIDES TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: q Check the air cleaner clogging caution pilot lamp more frequently to check the degree of clogging of the air cleaner. Clean the air cleaner element more frequently. q Clean the radiator core frequently to avoid clogging.
Page 228 MAINTENANCE GUIDES TO MAINTENANCE CHECKS AFTER INSPECTION AND MAINTENANCE: If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may lead to serious injury or property damage. Always do the following: q Checks after operation (with engine stopped) q Have any inspection and maintenance points been forgotten? q Have all inspection and maintenance items been performed correctly? q Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped...
Page 229 Komatsu distributor. q When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil.
Page 230 Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 231 Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts. CARRYING OUT KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed.
Page 232 Perform sampling at regular fixed intervals. q Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. STORING OIL AND FUEL q Keep indoors to prevent any water, dirt, or other impurities from getting in.
Page 233 Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. q Never install any electric components other than those specified by Komatsu. q External electro-magnetic interference may cause malfunction of the control system controller, before install- ing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 234 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 235 RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT q Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
Page 236 MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE AMBIENT TEMPERATURE Reservoir Fluid type Recommended Komatsu Fluids (Note.1) -30°C 30°C Komatsu EOS0W30 (Note.1) -25°C 40°C Komatsu EOS5W40 Engine oil pan Engine oil -20°C 40°C...
Page 237 Note. 1: HTHS (High-Temperature High-Shear Viscosity 150°C), specified by ASTM D4741 must be equal to or higher than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils. Note. 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Page 238 3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30% and 68%. RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor. 4-14...
Page 239 Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. 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 240 MAINTENANCE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS q Face seal Width Tightening torque Nominal - No. across Target value Permissible range of threads (a) flats (b) (mm) 9/16 -18UNF 35 - 63 3.5 - 6.5 11/16 -16UN 54 - 93 5.5 - 9.5 13/16 -16UN 10.5...
Page 241 These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance.
Page 242 MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Safety cirtical parts for periodic replacement Q'ty Replacement interval 1 Fuel hose (fuel cut off valve - fuel pre-filter) 2 Fuel hose (fuel pre-filter - right priming pump) 3 Fuel hose (right priming pump - right feed pump) 4 Fuel hose (fuel pre-filter - left priming pump) 5 Fuel hose (left priming pump - left feed pump) 6 Fuel hose (fuel filter - right feed pump)
Page 243 MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE) LUBRICATING ..............................4-454 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) REPLACE TRANSMISSION OIL FILTER ELEMENT..................4-584 WHEN REQUIRED CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT ................
Page 244 MAINTENANCE MAINTENANCE SCHEDULE CHART CHECK FAN BELT FOR WEAR ........................4-594 EVERY 1000 HOURS SERVICE CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER ............... 4-604 CLEAN TRANSMISSION CASE BREATHER ....................4-614 REPLACE FUEL MAIN FILTER CARTRIDGE....................4-624 LUBRICATING ..............................4-644 TIGHTEN ROPS CANOPY ..........................4-664 REPLACE CORROSION RESISTOR CARTRIDGE (Only when corrosion resistor cartridge is used) ....
Page 245: Lubricating
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE) Carry out the following maintenance every 10 hours for the first 50 hours of operation of a new machine. q Lubricating For details of the service procedure, see the section on EVERY 100 HOURS SERVICE. INITIAL 250 HOURS SERVICE Perform the following maintenance only after the first 250 hours.
Page 246: When Required
MAINTENANCE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT WARNING q If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. q When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 247 MAINTENANCE SERVICE PROCEDURE 5. Direct dry compressed air (Max. 0.69 MPa (7 kg/cm ) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside. 1) If the air cleaner clogging caution pilot lamp flashes imme- diately after the outer element has been cleaned, replace both the inner and outer elements.
Page 248: Clean Inside Of Cooling System
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 249 If it gets into your eyes, wash your eyes immediately with ample water, then consult a doctor for treatment. Always use Komatsu genuine super coolant (AF-NAC) for the coolant. Use tap water to dilute the coolant. If river water or well water or simple water supply must be used, please consult your Komatsu distributor.
Page 250 MAINTENANCE SERVICE PROCEDURE 1. Stop the machine in a horizontal place. 2. Stop the engine. 3. Open engine side cover (1). 4. Tighten valve (3) of corrosion resistor (2). (Only when corrosion resistor is used) 5. Loosen radiator cap (4) slightly to release the pressure, then remove the cap.
Page 251 MAINTENANCE SERVICE PROCEDURE 14. Replace corrosion resistor (2). For details of the procedure for replacing the corrosion resistor, see “REPLACE CORROSION RESISTOR CAR- TRIDGE (4-67)“. (Only when corrosion resistor is used) 15. Open valve (3) of corrosion resistor (2). (Only when corrosion resistor is used) 16.
Page 252: Check Transmission Oil Level, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK TRANSMISSION OIL LEVEL, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. Carry out this procedure if there is any sign of oil on the trans- mission case, or if there is oil mixed with the cooling water.
Page 253: Check Axle Oil Level, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK AXLE OIL LEVEL, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. Perform this procedure if there is any sign of oil on the axle case.
Page 254: Clean Air Conditioner Condenser
MAINTENANCE SERVICE PROCEDURE CLEAN AIR CONDITIONER CONDENSER WARNING q Do not wash the condenser with a steam cleaner. There is danger that the condenser could overheat. q If high-pressure water hits your body directly or dirt is sent flying, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment.
Page 255: Clean Radiator, Oil Cooler, Aftercooler Fins
MAINTENANCE SERVICE PROCEDURE CLEAN RADIATOR, OIL COOLER, AFTERCOOLER FINS WARNING If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the com- pressed air, high-pressure water, or steam, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment.
Page 256: Replace Bucket Teeth
REMARK If it cannot be removed by this method, for safety reasons, always contact your Komatsu distributor to have the replace- ment carried out. 4. Clean bucket and adapter (3).
Page 257: Lubricating
MAINTENANCE SERVICE PROCEDURE LUBRICATING 1. Using a grease pump, pump in grease through the grease fittings shown by arrows. 2. After greasing, wipe off any old grease that was pushed out. (1) Work equipment control valve linkage (2 places) If the work equipment control lever is heavy or does not move smoothly, apply grease.
Page 258: Check Air Conditioner
Colorless, transparent: No refrigerant (C) REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributors to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 259: Bleeding Air From Brake Hydraulic Circuit
Then, depress the pedal to the end and tighten bleeder screw (1) while the oil is flowing out. NOTICE Bleed the air at all 4 locations. After bleeding the air, check the oil level in the brake oil tank. For details, contact your Komatsu distributor. 4-35...
Page 260: Replace Slow Blow Fuse
2. Put bucket control lever in DUMP position and lift arm control lever in RAISE position, and after cylinder reaches stroke end, keep in that position for one minute. For details, contact your Komatsu distributor. REPLACE SLOW BLOW FUSE NOTICE...
Page 261: Bleeding Air From Hydraulic Tank
MAINTENANCE SERVICE PROCEDURE BLEEDING AIR FROM HYDRAULIC TANK After replacing oil and filter element or cleaning strainer, bleed the air from the circuit. When changing the oil in the hydraulic tank, or removing the piston pump, or removing the piping of the piston pump, bleed the air in the following way after assembling.
Page 262 MAINTENANCE SERVICE PROCEDURE BLEEDING AIR FROM HYDRAULIC CIRCUIT 1. Check that the hydraulic oil in the hydraulic tank is at the specified level. 2. Run the engine at low idle, and extend and retract the steering, bucket, and lift arm cylinders 4 to 5 times. Be careful not to operate the cylinder to the end of its stroke (stop approx.
Page 263: Replace Fan Belt, Adjust Auto-Tensioner
MAINTENANCE SERVICE PROCEDURE REPLACE FAN BELT, ADJUST AUTO-TENSIONER Replace the V-belts if they contact the bottom of the pulley grooves, if they are lower than the outside diameter of the pulleys, or if they are cracked or flaking. REPLACEMENT 1. Loosen locknut (2), then loosen the adjustment bolt (1), and remove it from yoke (3) with locknut (2) still fitted.
Page 264 MAINTENANCE SERVICE PROCEDURE ADJUSTMENT 1. Install adjustment bolt (1) and locknut (2) to yoke (3). 2. Tighten adjustment bolt (1) until the clearance between pin (6) of the tension pulley (5) and the end face of the oblong hole of yoke (3) is 0 mm, then tighten a further 6 turns. Lock securely with locknut (2).
Page 265: Selection And Inspection Of Tires
Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the fol- lowing table. Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when using optional tires.
Page 266 MAINTENANCE SERVICE PROCEDURE CHECK INFLATION PRESSURE OF TIRES WARNING When inflating a tire, check that no one will enter the work- ing area. Use an air chuck which has a clip and which can be fixed to the air valve. While inflating the tire, check the inflation pressure occa- sionally so that it will not rise too high.
Page 267: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For the following items, see “CHECK BEFORE STARTING (3-69)“. q Checking with machine monitor q Check dust indicator q Drain water from fuel pre-filter q Check coolant level, add coolant q Check oil level in engine oil pan, add oil q Check brake oil tank level, add oil q Check fuel level, add fuel q Check electric wiring...
Page 268: Every 50 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE DRAIN WATER, SEDIMENT FROM FUEL TANK 1. Prepare a container to catch the fuel and place it under the fuel tank. 2. Open the drain valve (1) on the right side of the fuel tank and drain out all the water and sediment collected at the bottom of the tank.
Page 269: Every 100 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 100 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATING (Applicable for machines with no auto greasing system installed.) NOTICE q In the extremely hard working conditions, grease the following pins (1) through (6) every 10 hours of operation or daily, whichever way is deemed appropriate.
Page 270 MAINTENANCE SERVICE PROCEDURE (4) Backet cylinder pin (2 places) (5) Bellcrank pin (1 place) (6) Lift cylinder pin (4 places) (7) Steering cylinder pin (4 places) 4-46...
Page 271: Check Oil Level In Hydraulic Tank, Add Oil
MAINTENANCE SERVICE PROCEDURE (8) Rear axle pivot pin (3 places) CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 272: Clean Element In Air Conditioner Fresh Air Filter
MAINTENANCE SERVICE PROCEDURE CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. If the air conditioner has been used, the air filter should be cleaned. Stop the air conditioner before cleaning the element.
Page 273: Every 250 Hours Service
If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4-49...
Page 274: Check Parking Brake
1. Set the machine on a dry downhill slope, press the parking brake switch to the ON position, and check if the parking brake hold the machine in position. 2. If any problem is found, please contact your Komatsu distributor. 4-50...
Page 275: Check Alternator Belt Tension, Adjust
MAINTENANCE SERVICE PROCEDURE CHECK ALTERNATOR BELT TENSION, ADJUST Carry out the inspection and adjustment work after removing cover (1). CHECKING The belt should normally deflect by about 20 mm when pressed with the finger (with a force of approx. 58.8 N (6 kg) at a point midway between the drive pulley and alternator pulley.
Page 276: Check Air Conditioner Compressor Belt Tension, Adjust
MAINTENANCE SERVICE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST Carry out the inspection and adjustment work after removing cover (1). CHECKING The deflection should be approx. 12.5 to 16.5 mm when pressed with a finger force of approx. 98.1 N (10 kg) at a point midway between the air conditioner compressor pulley and drive pulley.
Page 277: Check For Loose Wheel Hub Nuts, Tighten
If the brake oil pressure caution lamp lights up when the brake has been depressed 5 or less times, the gas pressure in the accumulator has probably dropped. Please contact your Komatsu distributor to have the accumulator inspected.
Page 278: Every 500 Hours Service
Use the supplied hose to prevent oil from spraying out into the surrounding area. 6. Check the drained oil, and if there are excessive metal par- ticles or foreign material, please contact your Komatsu dis- tributor. 7. Tighten drain plug (P), then remove the hose.
Page 279 MAINTENANCE SERVICE PROCEDURE 8. Using the filter wrench, turn filter cartridge (1) counter- clockwise to remove it. In particular, if this operation is carried out immediately after stopping the engine, a large amount of oil will come out, so wait for 10 minutes before starting the operation. 9.
Page 280: Replace Fuel Pre-Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 281 MAINTENANCE SERVICE PROCEDURE 2. Remove transparent cup (2) from the filter and inspect it. If it is broken or damaged, replace it with a new part. 3. Clean transparent cup (2) and remove seal (3). Coat the new seal with clean fuel or oil. 4.
Page 282: Replace Transmission Oil Filter Element
MAINTENANCE SERVICE PROCEDURE REPLACE TRANSMISSION OIL FILTER ELEMENT WARNING q The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before cleaning the engine breather. q When using compressed air, there is a hazard that dirt may be blown up and cause serious injury.
Page 283: Lubricate Center Drive Shaft
MAINTENANCE SERVICE PROCEDURE LUBRICATE CENTER DRIVE SHAFT (3 places) CAUTION If you fail to grease the drive shaft, the shaft will break, and there is danger that the broken shaft will cause serious damage to the machine. To avoid this problem always maintain the specified greasing interval strictly.
Page 284: Every 1000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Maintenance for every 50, 100, 250 and 500 hours service should be carried out at the same time. CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns.
Page 285: Clean Transmission Case Breather
MAINTENANCE SERVICE PROCEDURE 7. Remove bolt (6), then remove cover (7) and take out strainer (9) together with spring (8). 8. Remove any dirt stuck to strainer (9), then wash it in clean diesel oil or flushing oil. If strainer (9) is damaged, replace it with a new part.
Page 286: Replace Fuel Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 287 MAINTENANCE SERVICE PROCEDURE 6. Remove filter cartridge cap (A) and install to the filter holder. NOTICE Do not fill the filter cartridge with fuel. Cap (A) is installed to prevent dirt from entering the inside of the filter cartridge. 7. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn.
Page 288: Lubricating
MAINTENANCE SERVICE PROCEDURE LUBRICATING 1. Using a grease pump, pump in grease through the grease fittings marked by the arrows. 2. After greasing, wipe off any old grease that was pushed out. Applicable for machines with no auto greasing system installed to positions (1), (2), or (7). (1) Center hinge pin (2 places) CAUTION If you fail to grease the drive shaft, the shaft will break, and there is danger that the broken shaft will cause...
Page 289 MAINTENANCE SERVICE PROCEDURE (3) Front drive shaft (3 places) (4) Rear drive shaft (2 places) (5) Upper drive shaft (3 places) (6) Parking brake linkage (6 places) 4-65...
Page 290: Tighten Rops Canopy
ROPS canopy. If any bolt is loose, tighten it. Tightening torque: 2452 to 3040 Nm (250 to 310 kgm) 3. Install the cover. The tightening torque is large, so a power wrench is needed when tightening. Please request your Komatsu dis- tributor to carry out this work. 4-66...
Page 291: Replace Corrosion Resistor Cartridge (Only When Corrosion Resistor Cartridge Is Used)
MAINTENANCE SERVICE PROCEDURE REPLACE CORROSION RESISTOR CARTRIDGE (Only when corrosion resistor cartridge is used) WARNING All the engine parts are at high temperature after the engine has been operated, so never replace the car- tridge immediately after finishing operations. Wait for the oil to cool down before replacing the cartridge. q Prepare a filter wrench 1.
Page 292: Check Of Engine Air Intake Piping Clamps For Looseness
MAINTENANCE SERVICE PROCEDURE CHECK OF ENGINE AIR INTAKE PIPING CLAMPS FOR LOOSENESS Check for any looseness in clamps (1) and (2) of the hoses between air cleaner (A) and turbocharger (B). Tighten any loose clamps. Check for any looseness in clamps (3) and (4) of the hoses between turbocharger (B) and aftercooler (C) and the engine.
Page 293: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns.
Page 294 MAINTENANCE SERVICE PROCEDURE CAUTION When removing the filter cover, keep the filter pressed down by hand. The filter cover is being pushed by a spring, so if the filter cover mounting bolts are removed carelessly, there is danger that the filter cover will spring out and cause injury.
Page 295 MAINTENANCE SERVICE PROCEDURE 18. Loosen plug (9) installed above the tube on the suction side of the piston pump, and also loosen plug (10) installed on the elbow in the upper part of the piston pump. There is a plug on each pump, so loosen all 6 plugs. 19.
Page 296: Clean Hydraulic Tank Strainer
MAINTENANCE SERVICE PROCEDURE CLEAN HYDRAULIC TANK STRAINER When changing the oil in the hydraulic tank, drain the oil from the tank and clean the strainer. 1. Loosen bolts (1) and (3), then remove covers (2) and (4). 2. Loosen bolt (5), remove strainer cover (6), then remove strainer (8) together with spring (7).
Page 297: Replace Hydraulic Tank Breather Element
MAINTENANCE SERVICE PROCEDURE REPLACE HYDRAULIC TANK BREATHER ELEMENT WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
Page 298: Change Axle Oil
MAINTENANCE SERVICE PROCEDURE CHANGE AXLE OIL WARNING q The parts and oil are at high temperature after the engine is stopped, and may cause burns.Wait for the temperature to go down before starting the work. q When removing the plug, oil may spurt out, so turn the plug slowly to release the internal pressure, then remove it carefully.
Page 299 MAINTENANCE SERVICE PROCEDURE 3. Remove drain plug (3) to drain the oil. 4. Stop the machine so that drain plug (4) of the final drive is at the bottom. Remove oil filler plug (5) and drain plug (4), and fit the tube of attached tool in hole of plug (4) and drain the oil.
Page 300: Change Brake Oil
MAINTENANCE SERVICE PROCEDURE CHANGE BRAKE OIL WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. q Refill capacity: 31 liters q Prepare a container to catch drain fuel.
Page 301: Replace Filter Element In Brake Oil Tank
MAINTENANCE SERVICE PROCEDURE REPLACE FILTER ELEMENT IN BRAKE OIL TANK WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 302: Replace Brake Oil Tank Breather
MAINTENANCE SERVICE PROCEDURE REPLACE BRAKE OIL TANK BREATHER WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
Page 303: Check Alternator, Starting Motor
CHECK ALTERNATOR, STARTING MOTOR When carrying out the EVERY 2000 HOURS SERVICE or EVERY YEAR SERVICE, remove the belt and check that the alternator rotates smoothly. If it does not rotate smoothly, please ask your Komatsu distributor to carry out inspection and repair.
Page 304: Checking Function Of Accumulator
If the work equipment stops while it is moving, the gas pressure in the accumulator has probably dropped. Please contact your Komatsu distributor to have the accumulator inspected. Replace the accumulator every 4000 hours or every 2 years.
Page 305: Every 4000 Hours Service
Komatsu distributor for disassembly and repair or replacement. CHECK STARTING MOTOR The brush may be worn or have no grease on the bearing, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
Page 306: Check For Loose Engine High-Pressure Piping Clamps, Hardening Of Rubber
Check visually and touch by hand to check that there are no loose mounting bolts for high-pressure piping clamps (1) - (34) in the diagram and no hardening of any rubber parts. If any problem is found, the part must be replaced. In this case, please ask your Komatsu distributor to carry out the replacement. Right...
Page 307: Checking For Missing Fuel Spray Prevention Cap, Hardening Of Rubber
Check visually that there are no missing caps or loose bolts, and feel with your finger to check that the rubber has not hardened. If there is any problem, the problem part must be replaced. Contact your Komatsu distributor for part replacement. Right...
Page 308: Every 8000 Hours Service
Contact your Komatsu distributor to have the engine high-pressure clamps replaced. REPLACE FUEL SPRAY PREVENTION CAP Contact your Komatsu distributor to have the fuel spray prevention cap replaced. OVERHAUL STARTING MOTOR AND ALTERNATOR Ask your Komatsu distributor to carry out this work.
Page 309 SPECIFICATIONS...
Page 310 WA900-3E0 Operating weight 101900 107200 (including 1 operator: 80 kg) Normal load 19800 23400 Bucket capacity Engine model Komatsu SAA12V140E diesel engine Engine horsepower kW{HP}/rpm 603{808}/2000 638{855}/2050 A Overall length (including teeth) 13960 14485 B Overall height 5275 C Bucket overall height (When bucket lifted)
Page 311 ATTACHMENTS, OPTIONS WARNING Please read and make sure that you understand the SAFETY section before reading this section.
Page 312 Soft ground The displayed travel speed changes according to the tire size, so when installing optional tires, please contact your Komatsu distributor. On jobsites where there are boulders or sharp rocks, install tire protectors (mesh chain). (*): In the case of WA900-3E0, do not fit a tire protector (mesh chain type) to the rear wheels.
Page 313 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM HANDLING AUTO-GREASING SYSTEM With this system, the grease is automatically supplied through the conmputer controls. 1. Check that a can or grease is in the grease pump case. If the grease level is low, fill with grease. 2.
Page 314 If on the other hand the lamp does not stop flashing (i.e. does not light up) even though grease has been suffi- ciently added, then there is something wrong with the machine. In that case, stop the machine at once and consult your Komatsu distributor. METHOD OF OPERATING AUTO-GREASING SYSTEM 1.
Page 315 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM 1) One person removes plug (4) from one injector, then stays there. This plug (4) is installed to the manifold end of each end injector. If air must be bled from the main piping, remove this plug. 2) The other person presses the auto-greasing switch to start the grease pump.
Page 316 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM 6. Filling branch lines (Injector - Pin) with grease Remove cap (11) of filler fitting (10) of injector (9), then fill the all branch lines with grease by using a hand grease gun. 7. Check of supply line pressure Check grease pump pressure gauge (12) and supply grease line pressure gauge (13).
Page 317 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM 8. Check of operation of injector Turn ON the auto-greasing switch, and check that indicator pin (14) of injector (SL-1, SL-11) is operating normally.
Page 318 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM 9. Adjustment of greasing rate and injector q Adjust the injector to change the greasing rate for 0 - 30 hours (First step), 30 - 150 hours ((Second step) and after 150 hours after the auto-greasing system installed. q Set the interval to 11.25 minutes.
Page 319 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM Greasing points (Loader linkage) Section Q (Right) (Right) (Left) (Left) Section P (right side of machine body) Bucket hinge Bucket cylinder rod Bucket link (front) Bellcrank center Bucket link (rear) Lift arm cylinder rod...
Page 320 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM Greasing points (Front frame and rear frame) Rear frame Front frame (Left) (Right) (Left) (Right) (Left) (Right) (Right) (Left) View Z (front frame side) View X (rear frame side) Bucket cylinder bottom (13) Center hinge pin (lower) Lift arm cylinder bottom (14) Rear axle support (front) Lift arm pivot (right)
Page 321 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM METHOD OF ADJUSTING DISCHARGE FROM INJECTOR 1. Injector (SL1) 1) The injector is operated by the pressure from the pump, and it feeds grease of the specified quantity to the bearing. 2) To see if the injector works normally, check the operation of indicator pin (1) on its head.
Page 322 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM 2. Injector (SL11) 1) The injector is operated by the pressure from the pump, and it feeds grease of the specified quantity to the bearing. 2) To see if the injector works normally, check the operation of indicator pin (4) on its head.
Page 323 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM METHOD OF SETTING TIMER q The timer is installed to control the greasing interval of the auto-grease system. q The timer is installed in box (1) at the rear of the operator's seat. q The greasing interval can be changed freely according to the following table with the blue dial of the timer. The set interval has an error of about ±...
Page 324 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM 2. Method of adjusting interval time (Blue dial) Open the door at the rear lower of the cab, then open the timer box. Turn the dial shown at right to adjust the interval Dial (red) Dial (blue) time and operating time.
Page 325 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM 3. Method of adjusting operating time (Red dial) To adjust the operating time, turn red rotary switch 1 in the figure at right according to the following table. (Normally, fix Dial blue Dial (red) this dial to position 8 (60 seconds).) Position of switch Greasing interval (min) 22.5...
Page 326 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM METHOD OF CHARGING WITH GREASE MACHINE EQUIPPED WITH COUPLER WARNING The charging point for the grease is at the center hinge. To prevent yourself from getting caught between the work equipment, stop the engine before charging with grease. Charge with grease from coupler (1) at the center hinge por- tion.
Page 327 ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM MACHINE NOT EQUIPPED WITH COUPLER 1. Remove grease pump mounting bolts (1). 2. Remove grease pump (2) and follower plate (3) from grease pump case (4). 3. Fill the inside of grease pump case (4) with grease. When using a pail can, replace the pail can.
Page 328 Komatsu distributor before selling or exporting any machine equipped with VHMS. q When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary, it may be necessary for your Komatsu distributor to remove the VHMS equipment or to carry out action to stop communications.
Page 329 ATTACHMENTS, OPTIONS HANDLING MACHINES EQUIPPED WITH VHMS NOTICE q Please contact your Komatsu distributor before installing a top guard or other attachment that covers the antenna. q Be careful not to get water on the communications terminal or wiring. REMARK The communications terminal uses wireless communications, so it cannot be used inside tunnels, underground, inside buildings, or in mountain areas where radio waves cannot be received.
Page 330 ATTACHMENTS, OPTIONS HANDLING MACHINES EQUIPPED WITH VHMS 6-20...
Page 331 INDEX...
Page 332 INDEX...
Page 333 INDEX INDEX <A> VHMS COMMUNICATIONS TERMINAL INSTALLED ..............6-18 ADJUSTING WORK EQUIPMENT POSTURE ...3-124 VHMS INSTALLED, COMMUNICATIONS TERMINAL AIR CONDITIONER............3-60 NOT INSTALLED .............6-18 AM/FM RADIO-CASSETTE STEREO......3-52 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ..............4-5 <B> HANDLING THE TIRES ..........3-132 BACKUP ALARM............3-45 HANDLING WIRELESS..........3-65 <C>...
Page 334 <R> WORK POSSIBLE USING WHEEL LOADER.....3-104 RECOMMENDED FUEL, COOLANT, AND LUBRICANT .............4-11 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ............4-14 FUEL, COOLANT LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ..4-12 REMOTE POSITIONER ..........3-101 REMOVAL AND INSTALLATION OF THE BUCKET ..3-125 <S>...
Page 335 COLOPHON...

This manual is also suitable for:

Wa900-3e0 series

Komatsu WA800-3E0 Series Operation & Maintenance Manual

Foreword

Foreword

Safety Information

Introduction

Necessary Information

Safety

Safety 2

Safety Labels

General Precautions

Precautions for Operation

Precautions for Maintenance

Precautions with Tires

Operation

General View

Explanation of Components

Operation

Maintenance Schedule Chart 4

Initial 250 Hours Service (Only after the First 250 Hours)

When Required

Check before Starting

Every 50 Hours Service

Every 100 Hours Service

Every 250 Hours Service

Every 500 Hours Service

Every 1000 Hours Service

Every 2000 Hours Service

Every 4000 Hours Service

Every 8000 Hours Service

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Summary of Contents for Komatsu WA800-3E0 Series

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Table of Contents