Page 2 This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
Page 3 1. FOREWORD...
Page 4 1. FOREWORD...
Page 5 Safety precautions are described in SAFETY from page 1-1. Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions.
Page 6 If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user.
Page 7 3. INTRODUCTION 3.4 VISIBILITY FROM OPERATOR’S SEAT The visibility standards (ISO 5006) for this machine require a view shown in the diagram below. 3.4.1 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 8 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 4.1 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. 4.2 ENGINE SERIAL NO. PLATE POSITION On the right of the cylinder block, when seen from the fan side.
Page 9 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No.: Engine serial No.: Product identification number (PIN): Distributor name: Address: Phone: Service personnel for your machine: REMARKS...
Page 10 5. CONTENTS 1. Foreword ............................0- 1 2. Safety information ..........................0- 4 3. Introduction ............................0- 5 4. Location of plates, table to enter serial No. and distributor ............0- 7 SAFETY 6. General precautions .......................... 1- 2 7. Precautions during operation ......................1- 8 Before starting engine ......................
Page 11: Table Of Contents
5. CONTENTS 12. Operation ............................2-33 12.1 Check before starting engine ....................2-33 12.2 Starting engine ........................2-49 12.3 Operations and checks after starting engine ............... 2-51 12.4 Moving machine off ........................ 2-52 12.5 Changing gear speed ......................2-54 12.6 Changing direction ........................
Page 12 20.1 Use of fuel, coolant and lubricants according to ambient temperature ......3-11 20.2 Recommended brands, recommended quality for products other than Komatsu genuine oil ................3-12 21. Standard tightening torques for bolts and nuts ................3-13 21.1 Introduction of necessary tools .....................
Page 13 5. CONTENTS 29. Handling joystick steering system ....................5- 8 29.1 Explanation of components ....................5- 8 29.2 Structure and function of joystick steering ................5- 9 29.3 Operation method of joystick steering system ..............5-12 29.4 Precautions for steering with joystick .................. 5-14 29.5 Adjustment of joystick console .....................
Page 14 5. CONTENTS 38. Sound package specification ......................5-97 38.1 Outline of sound package ...................... 5-97 38.2 Service item ..........................5-98 38.3 Dimensions ..........................5-99 39. Handling brake cooling system ....................... 5-100 39.1 Explanation of components ....................5-100 39.2 Service procedure ........................5-101 40.
Page 15 SAFETY  WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death. This safety section also contains precautions for optional equip- ment and attachments.
Page 16  WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. SAFETY RULES ‡ Only trained and authorized personnel can operate and maintain the machine. ‡ Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
Page 17 6. 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. Before making any modifications, please consult your Komatsu distributor.
Page 18  WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. FIRE PREVENTION FOR FUEL AND OIL Fuel, oil, antifreeze and wind sprayed can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS. ‡...
Page 19 ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled. Komatsu does not use asbestos in its products, but if you handle materials containing asbestos fibers, follow the guidelines given below: ‡ NEVER use compressed air for cleaning.
Page 20 In such a case, please contact your Komatsu distributor for advice on the method of repair. Even if ROPS is installed, it can only provide proper protection if the operator wears the seat belt.
Page 21 ‡ Do not make any hole or bring any flame or heat close to the accumulator. ‡ Do not weld any boss to the accumulator. ‡ The gas must be released before disposing of the accumulator, so please ask your Komatsu distributor to do this.
Page 22 7. PRECAUTIONS DURING  WARNING: For reasons of safety, always OPERATION follow these safety precautions. 7.1 BEFORE STARTING ENGINE SAFETY AT WORKSITE ‡ Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. ‡ Check the terrain and condition of the ground at the worksite, and determine the best and safest method of operation.
Page 23  WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day’s work. Failure to carry out these checks may lead to serious injury or damage. ‡...
Page 24  WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. WHEN STARTING ENGINE ‡ Walk around your machine again just before mounting it, and check for people and objects that might be in the way. ‡...
Page 25  WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.2 AFTER STARTING ENGINE CHECKS AFTER STARTING ENGINE Failure to carry out the checks properly after starting the engine will lead to delays in discovery of abnormalities, and this may lead to serious injury or damage to the machine.
Page 26  WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. CHECK WHEN CHANGING DIRECTION To prevent serious injury or death, always do the following before moving the machine or the work equipment. ‡ Sound the horn to warn people in the area. ‡...
Page 27 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. 1-13...
Page 28  WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. TRAVELING ON SLOPES ‡ Traveling on slopes could result in the machine tipping over or slipping to the side. ‡ When traveling on slopes, keep the bucket approximately 20 – 30 cm (8 – 12 in) above the ground. In case of emergency, quickly lower the bucket to the ground to help the machine to stop.
Page 29  WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION PRECAUTIONS WHEN OPERATING ‡ Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or when dropping soil over a cliff, dump one pile, then use the next pile of soil to push the first pile.
Page 30  WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. METHOD OF USING BRAKES ‡ Do not put your foot on the brake pedal unless necessary. ‡ Do not depress the brake pedal repeatedly unless necessary. ‡...
Page 31  WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION WORKING ON LOOSE GROUND ‡ Do not operate the machine on soft ground. It is difficult to get the machine out again. ‡...
Page 32  WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. PRECAUTIONS IN COLD AREAS ‡ After completing operations, remove all water, snow, or mud stuck to the wiring harness, connector 1, switches, or sensors, and cover these parts. If the water freezes, it will cause malfunctions of the machine when it is next used, and this may lead to unexpected accidents.
Page 33 When traveling on public roads, check first with the relevant authorities and follow their instructions. ‡ The machine can be divided into parts for transportation, so when transporting the machine, please contact your Komatsu distributor to have the work carried out. 1-19...
Page 34  WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. 7.4 BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate hydrogen gas, so mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. ‡...
Page 35  WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause a fire, so always do as follows.
Page 36  WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. 7.5 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 “16.2 METHOD OF LIFTING MACHINE”.
Page 37 8.1 BEFORE CARRYING OUT MAINTENANCE NOTIFICATION OF FAILURE Carrying out maintenance not described in the Komatsu operation and maintenance manual may lead to unexpected failures. Please contact your Komatsu distributor for repairs. WARNING TAG ‡...
Page 38  WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. KEEP WORK PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip.
Page 39  WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ‡ When carrying out inspection and maintenance, park the machine on level ground where there is no danger of falling rocks or landslides, or of flooding if the land is low, then lower the work equipment to the ground and stop the engine.
Page 40 Hoses and other parts of the fuel, engine, hydraulic, and brake system are critical parts for ensuring safety, so they must be replaced periodically. Replacement of safety critical parts requires skill, so please ask your Komatsu distributor to carry out replacement.
Page 41  WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE USE OF LIGHTING ‡ When checking fuel, oil, battery electrolyte, or window washer fluid, always use lighting with anti- explosion specifications. If such lighting equipment is not used, there is danger of explosion. ‡...
Page 42  WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. 8.2 DURING MAINTENANCE PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer. Extra precaution should be used when grinding, welding, and using a sledge-hammer.
Page 43  WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE MAINTENANCE WITH CHASSIS RAISED ‡ When carrying out operations with the work equipment or chassis raised, lock the front and rear frames with the safety bar, return the control levers to HOLD, set the control lever safety lock to the LOCK position, and block the work equipment and chassis.
Page 44  WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. DO NOT DROP TOOLS OR PARTS INSIDE MACHINE ‡ When opening the inspection window or tank oil filler to carry out inspection, be careful not to drop any nuts, bolts, or tools inside the machine.
Page 45 ‡ Depending on the type of failure, please contact your Komatsu distributor for repairs. RULES TO FOLLOW WHEN ADDING FUEL OR OIL Fuel, oil, antifreeze, and window washer fluid can be ignited by a flame.
Page 46 If it is difficult to locate the leakage, always please contact your Komatsu distributor for repairs. ‡ If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
Page 47  WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE TIRE MAINTENANCE Disassembly, repair, and assembly of tires requires specialist equipment and skill, so please ask your specialist tire repair shop to carry out repairs. CHECKS AFTER INSPECTION AND MAINTENANCE Failure to carry out inspection and maintenance fully, or failure to check the function of various maintenance locations may cause unexpected problems and may even lead to personal injury or...
Page 48  WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. 8.3 TIRES HANDLING TIRES If a tire or a rim is handled wrongly, the tire may burst or may be damaged and the rim may be broken and scattered, and that can cause serious injury and death.
Page 49  WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR STORAGE OF TIRES ‡ As a basic rule, store the tires in a warehouse which unauthor- ized persons cannot enter. If you must store the tires outside, always erect a fence around the tires and put up a “No Entry”...
Page 50 There are other labels in addition to the safety labels listed as follows, so handle them in the same way. Safety labels may be available in languages other than English. To find out what labels are available, contact your Komatsu distributor. 9.1 POSITION FOR ATTACHING SAFETY LABELS 1-36...
Page 51 Follow instructions and warnings in manual and in labels on machine. Keep manual in machine cab near operator. Contact Komatsu distributor for a replacement manual. Please request part number 427-93-21221 for safety labels (1 – 3). 1-37...
Page 52 9. POSITION FOR ATTACHING SAFETY LABELS 4. Do not enter 6. Precautions for going close to electric cables (09801-13001) Crush Hazard. Can cause severe injury or death. When machine is being operated, never place yourself in articulated area of machine. 5.
Page 53 9. POSITION FOR ATTACHING SAFETY LABELS 8. Precautions when oil is at high temperature 11. High pressure warning (09659-53000) Explosion hazard • Keep away from frame. • Do not weld or drill. 09659-53000 Hot oil hazard. To prevent hot oil from spurting out: Turn engine off.
Page 54 9. POSITION FOR ATTACHING SAFETY LABELS 14. “Do not come near machine” sign (09812-03000) ¤ DANGER Keep a safe distance 09812-03000 15. “Do not modify ROPS” sign (09620-30201) 16. Jump start prohibited (09842-A0481) (This plate is stick on the starting motor.) 1-40...
Page 55: Operation
OPERATION...
Page 56 10. GENERAL VIEW 10.1 GENERAL VIEW OF MACHINE If directions are indicated in this section, they refer to the directions shown by the arrows in the diagram below.
Page 57 10. GENERAL VIEW 10.2 GENERAL VIEW OF CONTROLS AND GAUGES...
Page 58 11. EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is impor- tant to understand fully the methods of operating the equipment and the meanings of the displays. 11.1 MACHINE MONITOR The machine monitor system consists of the main monitor (in front of the operator’...
Page 59 Finally, there will be two beeps to indicate that the monitor check has been completed. If the monitor lamps do not light up, there is probably a failure or disconnection, so please contact your Komatsu distributor for inspection. When the starting switch is turned to the ON position, if the...
Page 60 11. EXPLANATION OF COMPONENTS 11.1.1 WARNING DISPLAYS 1. CENTRAL CHECK LAMP (CHECK)  WARNING If this monitor flashes, carry out inspection and maintenance of the appropriate location as soon as possible. ‡ 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 the central CHECK lamp will also flash.
Page 61 11. EXPLANATION OF COMPONENTS ‡ If there is any abnormality in the battery charging system when the engine is running, the battery charge caution pilot lamp will flash and the central CHECK lamp will also flash at the same time. If the lamps flash, check the charging circuit. 2.
Page 62 11. EXPLANATION OF COMPONENTS 4. ENGINE OIL LEVEL CAUTION PILOT LAMP This warns the operator that the level of the oil in the engine oil pan has dropped. When carrying out checks before starting: If the oil level in the engine oil pan is low, the caution pilot lamp and central CHECK lamp will flash.
Page 63 (red) flashes. If the pilot lamp does not flash, it indicates that there is an abnormal- ity, so please ask your Komatsu distributor to carry out repairs. Do not operate the machine until the problem has been removed.
Page 64 11. EXPLANATION OF COMPONENTS 11.1.2 METER DISPLAY PORTION PILOT DISPLAY When the starting switch is ON, the pilot display lights up when the display items are functioning. 1. PARKING BRAKE PILOT LAMP This lamp lights up when the parking brake is applied. 2.
Page 65 11. EXPLANATION OF COMPONENTS 3. FRONT WORKING LAMP PILOT LAMP This lamp lights up when the front working lamp is switched on. 4. REAR WORKING LAMP PILOT LAMP This lamp lights up when the rear working lamp is switched on. 5.
Page 66 11. EXPLANATION OF COMPONENTS METERS 8. FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank. E: Tank is EMPTY F: Tank is FULL The lamp should light up in the green range during operation. If it enters the red range during operation, the fuel gauge lamp and central CAUTION lamp will flash.
Page 67 11. EXPLANATION OF COMPONENTS 11. SERVICE METER This meter shows the total operation hours of the machine. The service meter advances while the engine is running - even if the machine is not traveling. While the engine is running, green pilot lamp on the service meter flashes to show the service meter advances.
Page 68 11. EXPLANATION OF COMPONENTS 11.2 SWITCHES 1. STARTING SWITCH This switch is used to start or stop the engine. OFF position The key can be inserted and removed at this position. When the key is turned to this position, the electric circuit is turned off and the engine stops.
Page 69 11. EXPLANATION OF COMPONENTS 2. TRANSMISSION CUT-OFF SWITCH  WARNING If the machine has to be started on a slope, always turn the transmission cut-off switch to OFF and depress the brake pedal. Then depress the accelerator pedal while releasing the left brake pedal to start the machine off slowly.
Page 70 11. EXPLANATION OF COMPONENTS 5. TRANSMISSION MANUAL SELECTION SWITCH (Machine equipped with auto shift) Press the push button to turn ON or OFF. If the switch is pressed once, the pilot lamp lights up and the system is switched ON. If it is pressed again, the pilot lamp goes out and the system is switched OFF.
Page 71 11. EXPLANATION OF COMPONENTS 7. HORN BUTTON When the button in the center of the steering wheel is pressed, the horn will sound. AE061220 8. HAZARD LAMP SWITCH  WARNING Use the hazard lamps only in emergencies. Using the hazard lamps when traveling will cause problems for other machines.
Page 72 11. EXPLANATION OF COMPONENTS 10. FRONT WIPER SWITCH Turn switch A to operate the front wiper. ‡ Switch position Window display Operation Intermittent wiper Low-speed wiper High-speed wiper ‡ If button B is kept pressed, washer fluid will be sprayed out on to the front glass.
Page 73 ‡ If the parking brake has been used as an emergency brake when traveling at high speed (near the maximum speed), contact your Komatsu distributor to have the parking brake checked for any abnormality. 2-19...
Page 74 11. EXPLANATION OF COMPONENTS 15. ENGINE LOW IDLING SELECTOR SWITCH The engine low idling speed can be switched between two levels with this switch. Press the push button to turn ON or OFF. If the switch is pressed once, the pilot lamp lights up and the system is switched ON. If it is pressed again, the pilot lamp goes out and the system is switched OFF.
Page 75 11. EXPLANATION OF COMPONENTS 17. HOLD SWITCH To fix the gear shift range when using automatic gear shifting, press the switch at the side of the lift arm control lever knob. The speed range displayed on the transmission indicator on the main monitor is fixed, and the HOLD display lights up.
Page 76 11. EXPLANATION OF COMPONENTS 11.3 CONTROL LEVERS, PEDALS 1. SPEED CONTROL LEVER This lever controls the travel speed of machine. This machine has a 3-FORWARD, 3-REVERSE speed transmis- sion. Place the speed control lever in a suitable position to obtain the desired speed range.
Page 77 11. EXPLANATION OF COMPONENTS 2. DIRECTIONAL LEVER This lever is used to change the direction of travel of the machine. The engine cannot be started if the directional lever is not at N (neutral). Position 1 : Forward Position N : Neutral Position 2 : Reverse REMARK The length of the lever can be adjusted to 3 stages (positions A,...
Page 78 11. EXPLANATION OF COMPONENTS 5. BUCKET CONTROL LEVER This lever operates the bucket. 1 TILT ( U ): 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 posi- tion of the positioner, and the lever is returned to the HOLD position.
Page 79 11. EXPLANATION OF COMPONENTS 7. BRAKE PEDALS  WARNING ‡ When traveling downhill, always use the right brake pedal, and use the braking force of the engine together with the brake. ‡ Do not use the brake pedal repeatedly more than necessary. If the brake is used too frequently, the brake will overheat.
Page 80 11. EXPLANATION OF COMPONENTS 11.4 STEERING COLUMN TILT LEVER  WARNING Stop the machine before adjusting the angle of the steering wheel. This lever allows the steering column to be tilted forward or backward. Pull the lever up and move the steering wheel to the desired position.
Page 81 11. EXPLANATION OF COMPONENTS TO OPEN THE CAP (For the hydraulic tank filler port) 1. Insert the key into the cap. Insert the key as far as it will go. If the key is turned before it is inserted all the way, it may break. 2.
Page 82 When an abnormality occurs such as to use the fuel stop lever, contact your Komatsu distributor. If the engine is stopped using the fuel stop lever, bleed the air from the circuit, before starting the engine again. For details, see “24.7.2 REPLACE FUEL FILTER CARTRIDGE”.
Page 83 11. EXPLANATION OF COMPONENTS 11.13 FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 84 11. EXPLANATION OF COMPONENTS Fuse box II Fuse Name of circuit capacity Front working lamp Rear working lamp Air conditioner 1 Air conditioner 2 Wiper, washer Transmission controller Cigarette lighter, radio Rotating lamp (if equipped) Side working lamp Auto-greasing (if equipped) L.H.
Page 85 11. EXPLANATION OF COMPONENTS 11.15 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 (13.8 in) long, 22 cm (8.7 in) wide and 18 cm (7.1 in) high can be placed easily and fixed with a band.
Page 86 Use the air bleed valve to release the gas. ‡ Every 2000 hours or once a year, please contact your Komatsu distributor to have the gas pressure checked. The accumulator for the brake is installed on the side of the brake component box on the left side of the rear frame.
Page 87: Check Before Starting Engine
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Page 88 12. OPERATION 1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses. If any abnormality is found, repair it. 2. Remove dirt and dust from around engine, battery, radiator Check if there is any dirt or dust accumulated around the engine or radiator.
Page 89 Check for any loose or damaged bolts. If any loose bolts are found tighten them to 2452 – 3050 N·m (250 – 310 kgf·m, 1808.3 – 2242.2 lbft). If any bolts are damaged, replace them with genuine Komatsu bolts. 13. Clean cab window Clean the cab window to ensure good visibility when operating the machine.
Page 90 12. OPERATION 14. Inspection of tires  WARNING If worn or damaged tires are used, they may burst and cause serious injury or death. To ensure safety, do not use the following tires. Wear: ‡ Tires with a tread groove of less than 15% of that of a new tire ‡...
Page 91 3 seconds and the alarm buzzer sounds for about 1 second. If any monitor lamp does not light up, ask your Komatsu distribu- tor to inspect that monitor lamp. Do not carry out the checks before starting using only the monitor;...
Page 92 12. OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL  WARNING The parts and oil are high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the opera- tion.
Page 93 12. OPERATION CHECK BRAKE OIL TANK LEVEL, ADD OIL  WARNING Always use engine oil to refill the brake oil tank. 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 94 12. 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 completely. Never bring flames near fuel because it is highly flammable and dangerous. 1.
Page 95 If the wall or rubber sheet are damaged or have come off, please contact your Komatsu distributor for repairs.
Page 96 12. OPERATION CHECK EFFECT OF PARKING BRAKE  WARNING Even if the parking brake switch 1 is turned ON, there is danger until parking brake pilot lamp 2 lights up, so keep brake pedal 3 depressed. Measurement conditions ‡ Tire inflation pressure: Specified pressure ‡...
Page 97 12. OPERATION CHECK EFFECT OF BRAKE Drive the machine at a speed of 20 km/h (12.4 MPH) on a dry flat concrete road surface, and check that the stopping distance is less than 7.5 m (24 ft 6 in). CHECK SOUND OF HORN AND BACKUP BUZZER CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...
Page 98 12. OPERATION 12.1.3 ADJUSTMENT BEFORE OPERATION AIR SUSPENSION SEAT  WARNING ‡ Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. ‡ Adjust the seat before starting operations or when changing operators.
Page 99 12. OPERATION F: Adjusting height of headrest Move the headrest up and down to the desired height. The adjustment range is 50 mm (2.0 in). G: Adjusting headrest angle Rotate the headrest to the front or rear. H: Adjusting angle of armrest Adjust the angle of the armrest by rotating knob 5.
Page 100 12. OPERATION ADJUST SEAT BELT Always install a seat belt on machines equipped with ROPS.  WARNING ‡ Before fitting the seat belt, check that there is no abnormality in the mounting bracket and mounting belt of the belt. If the belt is worn or damaged, replace it.
Page 101 12. 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.
Page 102 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 failure or disconnection, so please contact your Komatsu distributor for inspection. 2-48...
Page 103: Starting Engine
12. OPERATION 12.2 STARTING ENGINE 12.2.1 NORMAL STARTING  WARNING ‡ Start the engine only after sitting down in the operator’s seat. ‡ Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. ‡...
Page 104 12. OPERATION 12.2.2 STARTING IN COLD WEATHER  WARNING ‡ Start the engine only after sitting down in the operator’s seat. ‡ Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. ‡...
Page 105: Operations And Checks After Starting Engine
12. OPERATION 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE After starting the engine, do not immediately start operations. First, carry out the following operations and checks. NOTICE Do not suddenly accelerate the engine before the warming-up operation is completed. Do not run the engine at low idling or high idling continuously for more than 20 minutes.
Page 106: Moving Machine Off
12. OPERATION 12.4 MOVING MACHINE OFF  WARNING ‡ When moving the machine off, check that the area around the machine is safe, then sound the horn before starting. Do not allow people near the machine. There is a blind spot behind the machine, so be particularly careful when traveling in reverse.
Page 107 12. OPERATION 5. Set speed control lever 0 to the desired position. 6. Set directional lever A to the desired position. 7. Release right brake pedal 8, then depress accelerator pedal 3 to move the machine off. 2-53...
Page 108: Changing Gear Speed
12. OPERATION 12.5 CHANGING GEAR SPEED  WARNING When traveling at high speed, do not change the gear speed suddenly. When shifting gear, use the brakes to reduce the travel speed, then shift gear. Shift the gear as follows. Move speed control lever 1 to the desired position. Only 1st or 2nd speeds are used for digging and loading opera- tions, so actuate speed control lever stopper.
Page 109: Changing Direction
12. OPERATION 12.6 CHANGING DIRECTION  WARNING ‡ When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so be particularly careful when changing direction to travel in reverse. ‡...
Page 110 12. OPERATION F ↔ R Control for change of travel direction Gear speed Gear speed (Position of lever) at change of (Position of lever) travel direction (Command from controller) at change of travel Engine direction speed 1800 1 3rd & Caution 1600 1800...
Page 111: Turning
12. OPERATION 12.7 TURNING  WARNING ‡ It is dangerous to turn the machine suddenly at high speed, or to turn on steep hills. ‡ If the engine stops when the machine is traveling, the steer- ing cannot be used. This is particularly dangerous on hills, so never stop the engine when the machine is traveling.
Page 112: Stopping Machine
12. OPERATION 12.8 STOPPING MACHINE  WARNING ‡ Avoid stopping suddenly. Give yourself ample room when stopping. ‡ Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.
Page 113: Operation Of Work Equipment
12. OPERATION 12.9 OPERATION OF WORK EQUIPMENT Lift arm control lever 1 and bucket control lever 2 can be used to operate the lift arm and bucket as follows. LIFT ARM OPERATION (LEVER 1) 1 Raise ( J ) 2 Hold ( N ) The lift arm is kept in the same position. 3 Lower ( M ) 4 Float ( * ): The lift arm moves freely under external force.
Page 114: Work Possible Using Wheel Loader
12. OPERATION 12.10 WORK POSSIBLE USING WHEEL LOADER In addition to the following, it is possible to further increase the range of applications by using various attachments. 12.10.1 DIGGING OPERATIONS  WARNING Always set the machine facing directly to the front when carrying out digging or scooping operations.
Page 115 12. OPERATION 4. At the same time as thrusting the bucket into the material, raise the lift arm to prevent the bucket from going in too far. By raising the lift arm, ample traction will be produced by the front tires. REMARK If the bucket is thrust too much and the lift arm stops rising or the machine stops moving forward, release the accelerator pedal a...
Page 116 12. OPERATION ‡ When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the machine forward. Always be careful not to load the bucket on one side and cause an unbalanced load. This operation should be carried out in 1st gear.
Page 117 12. OPERATION 12.10.2 LEVELING OPERATIONS NOTICE Always operate the machine in reverse when carrying out leveling operations. If it is necessary to carry out leveling operations when traveling forward, do not set the bucket dumping angle to more than 20°. AE061970 1.
Page 118 12. OPERATION 12.10.5 LOADING OPERATIONS Select the method of operation which will give the minimum amount of turning and travel in order to provide the most efficient method for the jobsite.  WARNING ‡ Always keep the working area flat. Do not turn suddenly or apply the brake suddenly when traveling with a raised load.
Page 119: Precautions For Operation
If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine. NOTICE If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the parking brake checked for any abnormality. 12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES LOWER THE CENTER OF GRAVITY WHEN TURNING.
Page 120 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. ‡ When traveling with standard tires L-5 on a paved road surface, use the table as a guide.
Page 121: Adjusting Work Equipment Posture
12. OPERATION 12.12 ADJUSTING WORK EQUIPMENT POSTURE  WARNING ‡ Stop the machine on flat ground and put blocks in front and behind the wheels. ‡ Apply the parking brake. ‡ Secure the front and rear frames with the safety bar. ‡...
Page 122 12. OPERATION 12.12.2 ADJUSTING BUCKET POSITIONER 1. Lower the bucket to the ground and adjust the bucket to the desired digging angle. Set the bucket control lever at HOLD, stop the engine and adjust as follows. 2. Loosen two bolts 1 and adjust mounting bracket 4 of the proximity switch so that the rear tip of angle 2 is in line with the center of the sensing surface of proximity switch 3.
Page 123: Parking Machine
12. OPERATION 12.13 PARKING MACHINE  WARNING ‡ Avoid stopping suddenly. Give yourself ample room when stopping. ‡ Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.
Page 124: Checks After Completion Of Operation
12. OPERATION 4. Operate lift arm control lever 5 to lower the bucket to the ground. 5. Lock lift arm control lever 5 and bucket control lever 6 with safety lock 7. 12.14 CHECKS AFTER COMPLETION OF OPERATION Check the engine water temperature, engine oil pressure, torque converter oil temperature, and fuel level with the meter and lamps.
Page 125: Check After Stopping Engine
12. OPERATION 12.16 CHECK AFTER STOPPING ENGINE 1. Walk around the machine and check the work equipment, body work, and undercarriage, and check also for leakage of oil and water. If any leakage or abnormality is found, carry out repairs. 2.
Page 126: Handling The Tires
ﬁ When the bead is damaged ﬁ For tubeless tires, when there is air leakage or improper repair Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. 12.18.2...
Page 127 If this is not done, the tires will be damaged, so contact your Komatsu distributor or tire dealer when selecting tires. 2-73...
Page 128: Removal And Installation Of The Bucket
12. OPERATION 12.19 REMOVAL AND INSTALLATION OF THE BUCKET  WARNING Park the machine on level ground, set safety bar 3 on the frame, ground the bucket, shut down the engine, apply the parking brake 2 and place blocks 1 under the tires. Remove or install the bucket in the following manner, if so required for the convenience of transportation.
Page 129 12. OPERATION 4. Pull out and remove bucket pin 7 on both sides of the bucket. 5. Disconnect lift arm and bucket. 2-75...
Page 130 12. OPERATION INSTALLING THE BUCKET  CAUTION Align the pin holes with each other by using a rod. Never put your finger in the holes. 1. Set cord ring 2 on top of lift arm boss 1 as shown in the diagram.
Page 131 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 “24.5 EVERY 100 HOURS SERVICE”. For details of removing and installing the bucket, please contact your Komatsu distributor. 2-77...
Page 132: Transportation
13.2 LOADING, UNLOADING WORK  WARNING This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor. 13.3 METHOD OF SECURING MACHINE Load the machine onto a trailer as follows: 1. Lower the work equipment slowly.
Page 133 13. TRANSPORTATION 6. Put blocks in front of and behind the wheels and secure the machine with chains or wire rope of a suitable strength to prevent the machine from moving during transportation. NOTICE Always retract the antenna and reassemble the mirrors so that they are within the width of the machine.
Page 134: Method Of Lifting Machine
‡ 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. 2-80...
Page 135 13. TRANSPORTATION 13.4.1 LOCATION OF LIFTING POSITION MARK 13.4.2 WEIGHT TABLE Operating Front wheel Rear wheel Center of gravity weight load load (from front axle) 101550 kg 55750 kg 45800 kg 2425 mm WA900-3 (223918 lb) (122928 lb) (100989 lb) (7 ft 11 in) 2-81...
Page 136 13. TRANSPORTATION 13.4.3 LIFTING PROCEDURE Lifting work can be carried out only for machines with lifting marks. Before starting the lifting operation, stop the machine in a horizontal place and do as follows. 1. Start the engine, make sure that the machine is horizontal, then set the work equipment to the travel posture.
Page 137: Cold Weather Operation
‡ When changing the coolant or when handling coolant con- taining antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 138 14. COLD WEATHER OPERATION 14.1.3 BATTERY  WARNING ‡ The battery generates flammable gas. Do not bring fire or sparks near the battery. ‡ Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 139: Precautions After Completion Of Work
14. COLD WEATHER OPERATION 14.2 PRECAUTIONS AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions. ‡ Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rod clean to prevent damage to the seal caused by mud or dirt on the rod surface getting inside the seal together with drops of water.
Page 140: Warming-Up Operation For Steering Hydraulic Circuit In Cold Weather
14. COLD WEATHER OPERATION 14.4 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER  WARNING If the steering wheel is operated and stopped while the oil temperature is low, there may be a time lag before the machine stops turning. In this case, use the safety bar to ensure safety, and perform the warm-up operation in a wide place.
Page 141: Long-Term Storage
15.3 AFTER STORAGE 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.
Page 142: Troubleshooting
16. TROUBLESHOOTING 16.1 WHEN MACHINE RUNS OUT OF FUEL  WARNING The engine will start, so check carefully that the area around the engine is safe before cranking the engine. If the machine has run out of fuel, add fuel and then bleed the air from the fuel system before starting the engine.
Page 143: Method Of Towing Machine
Towing is only permitted in order to move a disabled machine to a place where it is possible to carry out inspection and maintenance. It must not be towed for long distances. ‡ Please consult your Komatsu distributor for information about towing a disabled machine. 2-89...
Page 144 16. TROUBLESHOOTING This machine must not be towed except in emergencies. When towing the machine, take the following precautions. ‡ 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. ‡...
Page 145 16. TROUBLESHOOTING 16.2.3 RELEASING PARKING BRAKE Please ask your Komatsu distributor to release the parking brake.  WARNING ‡ Stop the machine on a flat surface when releasing the parking brake, and check that the surroundings are safe. In emergen- cies or when the parking brake must be released on a hill, block the tires carefully before releasing the brake.
Page 146: If Battery Is Discharged
16. TROUBLESHOOTING 16.3 IF BATTERY IS DISCHARGED  WARNING ‡ When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position before starting. ‡ Before starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the battery.
Page 147 16. TROUBLESHOOTING PRECAUTIONS FOR CHARGING BATTERY Charging battery when mounted on machine Before charging, disconnect the cable from the negative . ‡ terminal of the battery. Otherwise, an unusually high voltage will damage the alternator. ‡ While charging the battery, remove all battery plugs for satisfac- tory ventilation.
Page 148 16. TROUBLESHOOTING 16.3.1 STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE  WARNING INCORRECT ‡ When connecting the cables, never contact the positive + and negative . terminals. ‡...
Page 149 16. TROUBLESHOOTING CONNECTING THE BOOSTER CABLES Keep the starting switch at the OFF position. Connect the booster cable as follows, in the order of the num- bers marked in the diagram. 1. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position.
Page 150: Other Trouble
16.4 OTHER TROUBLE 16.4.1 ELECTRICAL SYSTEM ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even ‡...
Page 151 16. TROUBLESHOOTING 16.4.2 CHASSIS ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Transmission Engine is running but machine ‡...
Page 152 16. TROUBLESHOOTING CHASSIS continued (16.4.2) Problem Main causes Remedy Disc brake Brake has no effect even when ‡ Low air pressure ‡ Charge air to specified pedal is depressed pressure ‡ Disc has reached wear limit (‡ Replace disc) ‡ Defective in hydraulic system ﬁ...
Page 153 16. TROUBLESHOOTING CHASSIS continued (16.4.2) 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 ‡...
Page 154 16. TROUBLESHOOTING 16.4.3 ENGINE ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor ‡...
Page 155 16. TROUBLESHOOTING ENGINE continued (16.4.3) Problem Main causes Remedy Combustion noise occasionally ‡ Defective nozzle (‡ Replace nozzle) makes breathing sound Abnormal noise generated ‡ Low grade fuel being used ‡ Change to specified fuel (combustion or mechanical) ‡ Overheating ‡...
Page 156 MAINTENANCE...
Page 157 17. GUIDES TO MAINTENANCE Do not carry out any inspection and maintenance operation that is not given in this manual. Perform maintenance work on hard, flat ground. Set to the inspection and maintenance posture. Always carry out operations with the machine in the following posture unless otherwise specified.
Page 158 Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu genuine oils: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Always use clean washer fluid: Use automobile window washer fluid and be careful not to let any dirt get into it.
Page 159 The rod end should be greased only when it becomes stiff after using it for long span of time. Controller: The controller for the machine monitor may be mistakenly actuated by interference from external electric waves. For this reason, when installing a radio or other such device, please consult your Komatsu distributor.
Page 160 For those who wish to use this service, please contact your Komatsu distributor. ‡ 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 161 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 162 Make sure that the oil is well mixed before sampling. • Perform sampling at regular fixed intervals. • Do not carry out sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu dis- tributor.
Page 163 ‡ External electro-magnetic interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, contact your Komatsu distributor. ‡ When working on the seashore, carefully clean the electric system to prevent corrosion.
Page 164 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 165 20. RECOMMENDED FUEL, COOLANT, AND LUBRICANT ‡ 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 166 20. RECOMMENDED FUEL, COOLANT, AND LUBRICANT 20.1 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Reservoir Axle Engine Transmission Hydraulic Cooling Brake (front and Pins Fuel tank oil pan case system system rear) (each) Capacity Liters 1065 — 1425 Specified US gal...
Page 167 20.2 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifications, refer to the Komatsu web page or consult your Komatsu distributor. 3-12...
Page 168 Hose nozzle for grease pump Grease cartridge 07950-90403 (Lithium base grease: 400 g) Nipple 424-98-11110 For hydraulic oil drain Hose 424-98-11120 Hammer 09039-00150 Plate 09963-03000 Warning tag If any of the above tools are broken, please order them from your Komatsu distributor. 3-13...
Page 169 The tightening torque is determined by the width across the flats of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 170 If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the safety critical parts. 3-15...
Page 171 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Part name Q’ty Replacement interval Fuel hose (Strainer – L.H. injection pump) Fuel hose (Injection pump – adapter) Fuel hose (L.H. injection pump – fuel tank) Fuel spill hose (Between nozzles) Turbochager lubricating hose Fuel hose (Strainer –...
Page 172 23. MAINTENANCE SCHEDULE CHART 23.1 MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE INITIAL 250 HOURS SERVICE (only after the first 250 hours) Replace fuel filter cartridge 3-21 Replace transmission oil filter element 3-21 Check engine valve clearance, adjust 3-21 WHEN REQUIRED Check, clean, or replace air cleaner element 3-22 Clean inside of cooling system...
Page 173 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE Bleeding air from hydraulic tank 3-40 Replace fan belt, adjust auto-tensioner 3-42 Selection and inspection of tires 3-43 Drain water from water separator (if equipped) 3-44 CHECK BEFORE STARTING Check monitor panel 3-45 Check coolant level, add water 3-45 Check oil level in engine oil pan, add oil...
Page 174 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE EVERY 100 HOURS SERVICE (continued) ‡ Tilt lever pin (1 point) 3-53 ‡ Lift cylinder pin (4 points) 3-54 ‡ Steering cylinder pin (4 points) 3-54 ‡ Rear axle pivot pin (3 points) 3-54 Check oil level in hydraulic tank, add oil 3-55...
Page 175 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE EVERY 1000 HOURS SERVICE (continued) ‡ Torque converter mount trunnion (1 point) 3-70 ‡ Fan pulley (1 point) 3-71 ‡ Tension pulley (2 points) 3-71 Check tightening parts of turbocharger 3-71 Clean fuel strainer 3-71 Tighten ROPS canopy 3-71...
Page 176 24. SERVICE PROCEDURE 24.1 INITIAL 250 HOURS SERVICE  WARNING Be sure to put a warning tag on work equipment control levers 1. Carry out the following maintenance only after the first 250 hours. ‡ REPLACE FUEL FILTER CARTRIDGE ‡ REPLACE TRANSMISSION OIL FILTER ELEMENT ‡...
Page 177 24. SERVICE PROCEDURE 24.2 WHEN REQUIRED  WARNING Be sure to put a warning tag on work equipment control levers 1. 24.2.1 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT  WARNING ‡ Never clean or replace the air cleaner element with the engine running.
Page 178 24. SERVICE PROCEDURE NOTICE If small holes or thinner parts are found on element when it is checked with an electric bulb after cleaning and drying, replace the element. When cleaning the element, do not hit it or beat it against anything.
Page 179 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 180 24. SERVICE PROCEDURE When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing table given below. It is actually better to estimate and temperature about 10°C (18°F) lower when deciding the mixing ratio.
Page 181 24. SERVICE PROCEDURE 1. Stop the engine and tighten corrosion resistor valve 1. 2. Raise the lever of radiator cap 2 to release the pressure, then remove the cap. 3. Prepare a container to catch the coolant, then open drain valves 3 and 4 of the radiator to drain the coolant.
Page 182 24. SERVICE PROCEDURE 9. Replace the corrosion resistor cartridge and open valve 1. For details of replacement of the corrosion resistor, see “24.8 EVERY 1000 HOURS SERVICE”. 10. Add coolant mixed with antifreeze until it overflows from the water filler. Decide the proportions of antifreeze and water according to the table for the mixing rate of water and antifreeze.
Page 183 24. SERVICE PROCEDURE 24.2.3 CHECK TRANSMISSION OIL LEVEL, ADD OIL  WARNING ‡ When checking the oil level, apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ The oil is at high temperature after the machine has been operated.
Page 184 24. SERVICE PROCEDURE 24.2.4 CHECK AXLE OIL LEVEL, ADD OIL  WARNING ‡ When checking the oil level, apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ The oil is at high temperature after the machine has been operated.
Page 185 24. SERVICE PROCEDURE 24.2.5 CHECK AXLE CASE BREATHER  WARNING When cleaning, apply the parking brake, and lock the front and rear frames with the safety bar and pin. Remove any mud or dust that is stuck to the area around the breather.
Page 186 Remove the electrical intake air heater from the engine intake connection, and check it for possible open-circuits and dirt. When inspecting and replacing the electrical intake air heater, replace the gasket with a new one. Ask your Komatsu distributor to check electrical intake air herater. 3-31...
Page 187 24. SERVICE PROCEDURE 24.2.10 REPLACE BUCKET TEETH  WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine, apply the parking brake and locks securely to the work equipment control levers.
Page 188 24. SERVICE PROCEDURE 24.2.11 LUBRICATING  WARNING ‡ Apply the parking brake switch, and lock the front and rear frames with the safety bar and pin. ‡ Set the work equipment in a stable condition, then stop the engine and locks the work equipment control levers with the safety lock lever.
Page 189 24. SERVICE PROCEDURE 2. Accelerator pedal linkage (2 points) If the accelerator pedal is heavy or does not return properly, apply grease. NOTICE Supply grease to following items 3 – 8 below every 10 operating hours or every day for the first 50 operating hours until the pins are braked on the new machine.
Page 190 24. SERVICE PROCEDURE 8. Lift cylinder pin (4 points) 3-35...
Page 191 At the same time, inspect the flow of refrigerant gas through the sight glass to check the gas level. Please contact your Komatsu distributor for this inspection. The sight glass is installed to the receiver on the right side of the air cleaner.
Page 192 5 on both sides is approx. 1.06 mm (0.042 in). Check the lining for wear and replace the pad if the thickness of the lining is reduced to less than 3 mm (0.12 in). Ask your Komatsu distributor for replacement of the pad. 3-37...
Page 193 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. 24.2.15 BLEEDING AIR FROM PPC CIRCUIT When removing piping of PPC circuit, or removing strainer, after...
Page 194 24. SERVICE PROCEDURE 24.2.16 REPLACE SLOW BLOW FUSE NOTICE ‡ Always turn the power OFF when replacing the slow blow fuse (turn the starting switch to the OFF position). ‡ Always replace the slow blow fuse with a fuse of the same capacity.
Page 195 4. Fix the cap of the hydraulic tank filler port. 5. Loosen the mouthpiece of the case drain hose 2, starting an engine at the condition of low idling. Tighten the mouthpiece, confirming that hydraulic oil flows from the mouthpiece. For details, contact your Komatsu distributor. 3-40...
Page 196 24. SERVICE PROCEDURE Bleeding air from hydraulic circuit. 1. Check that the oil reaches the specified level in the hydraulic tank. 2. Run the engine at low idling and operate each hydraulic cylin- ders (of steering, bucket and lift arm) 4 to 5 times, stopping 100 mm (3.94 in) from stroke end.
Page 197 24. SERVICE PROCEDURE 24.2.18 REPLACE FAN BELT, ADJUST AUTO-TENSIONER Replace the blet if the V-belt contacts the bottom of the pulley groove, or if the fan belt is lower than the outside edge of the pulley, or if there are any cracks, peeling, or other damage to the V-belt. Replacement 1.
Page 198 Select the tires according to the conditions of use and attach- ments of the machine. Use the following table. Since the indicated speed varies with the tire size, consult your Komatsu distributor when using optional tires. Maximum load...
Page 199 24. SERVICE PROCEDURE CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM  WARNING ‡ When inflating a tire, check that no one will enter the working area and use an air chuck which has a clip and which can be fixed to the air valve.
Page 200 3 seconds and the alarm buzzer sounds for about 1 second. If any monitor lamp does not light up, ask your Komatsu distribu- tor to inspect that monitor lamp. Do not carry out the checks before starting using only the monitor;...
Page 201 24. SERVICE PROCEDURE 24.3.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL  WARNING The parts and oil are high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the opera- tion.
Page 202 24. SERVICE PROCEDURE 24.3.4 CHECK BRAKE OIL TANK LEVEL, ADD OIL  WARNING Always use engine oil to refill the brake oil tank. 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 203 24. SERVICE PROCEDURE 24.3.5 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 completely. Never bring flames near fuel because it is highly flammable and dangerous. 1.
Page 204 If the wall or rubber sheet are damaged or have come off, please contact your Komatsu distributor for repairs.
Page 205 24. SERVICE PROCEDURE 24.3.9 CHECK EFFECT OF PARKING BRAKE  WARNING Even if parking brake switch 1 is turned ON, there is danger until parking brake pilot lamp 2 lights up, so keep brake pedal 3 depressed. Measurement conditions ‡ Tire inflation pressure: Specified pressure ‡...
Page 206 24. SERVICE PROCEDURE 24.3.10 CHECK EFFECT OF BRAKE Drive the machine at a speed of 20 km/h (12.4 MPH) on a dry flat concrete road surface, and check that the stopping distance is less than 7.5 m (24 ft 6 in). 24.3.11 CHECK SOUND OF HORN AND BACKUP BUZZER...
Page 207 24. SERVICE PROCEDURE 24.4 EVERY 50 HOURS SERVICE  WARNING Be sure to put a warning tag on work equipment control levers 24.4.1 DRAIN WATER, SEDIMENT FROM FUEL TANK Loosen valve 1 on the right side of the tank so that the sediment and water will be drained together with fuel.
Page 208 24. SERVICE PROCEDURE 24.5 EVERY 100 HOURS SERVICE  WARNING Be sure to put a warning tag on work equipment control levers Maintenance for every 50 hours should be carried out at the same time. 24.5.1 LUBRICATING  WARNING ‡ Apply the parking brake, and lock the front and rear frames with the safety bar and pin.
Page 209 24. SERVICE PROCEDURE 6. Lift cylinder pin (4 points) 7. Steering cylinder pin (4 points) 8. Rear axle pivot pin (3 points) 3-54...
Page 210 24. SERVICE PROCEDURE 24.5.2 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL  WARNING ‡ When the oil filler cap is removed, oil may spurt out, so stop the engine and wait for the oil temperature to go down, then turn the cap slowly to release the internal pressure before removing the cap.
Page 211 If distilled water is added to above the U.L line, use a pipette 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. 3-56...
Page 212 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. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTRO-...
Page 213 24. SERVICE PROCEDURE 24.6.2 CHECK ALTERNATOR BELT TENSION, ADJUST Checking The belt should normally deflect by about 20 mm (0.79 in) when pressed with the finger (with a force of approx. 58.8N (6 kgf) at a point midway between the drive pulley and alternator pulley. Adjusting 1.
Page 214 24. SERVICE PROCEDURE 24.6.3 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN If wheel hub nuts 1 are loose, tire wear will be increased and accidents may be caused. 1. Check for loose nuts, and tighten if necessary. When checking for loose nuts, always turn the nuts in the direction of tightening to check.
Page 215 2. Check all parts of the frame and boom for damage. In particular, check the colored part in the diagram, and repair if any cracks or other damage are found. For details of the method of repair, please contact your Komatsu distributor. 3-60...
Page 216 When draining the oil, fit the supplied vinyltube to the drain ports of the drain plug to prevent the oil from spraying out. 5. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 6. Install drain valve 1. 3-61...
Page 217 24. SERVICE PROCEDURE 7. Using the filter wrench, turn 4 full-flow filter cartridges 2 and 2 bypass filter cartridges 3 to the left to remove them. 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.
Page 218 24. SERVICE PROCEDURE 24.7.2 REPLACE FUEL FILTER CARTRIDGE  WARNING ‡ Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter. ‡ Do not bring fire or sparks near the fuel. Prepare a filter wrench and a container to catch the fuel.
Page 219 24. SERVICE PROCEDURE 24.7.3 REPLACE TRANSMISSION OIL FILTER ELEMENT  WARNING ‡ Apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ The oil is at high temperature immediately after the machine has been operated.
Page 220 24. SERVICE PROCEDURE 24.7.4 LUBRICATE CENTER DRIVE SHAFT (3 points)  WARNING ‡ Apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.
Page 221 24. SERVICE PROCEDURE 24.7.5 CHECK FAN BELT FOR WEAR Check the V-belt and when the following conditions exist, re- place or adjust the V-belt. ‡ When the V-belt makes contact with the bottom of the groove in each pulley. ‡ When the V-belt is worn, and its surface is lower than the outer diameter of the pulley.
Page 222 24. SERVICE PROCEDURE 24.8 EVERY 1000 HOURS SERVICE  WARNING Be sure to put a warning tag on work equipment control levers Maintenance for every 50, 100, 250 and 500 hours should be carried out at the same time. 24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER ...
Page 223 24. SERVICE PROCEDURE 5. Remove bolt 4, then remove cover 5 and take out strainer 7 together with spring 6. 6. Remove any dirt stuck to strainer 7, then wash it in clean diesel oil or flushing oil. If strainer 7 is damaged, replace it with a new part.
Page 224 24. SERVICE PROCEDURE 24.8.3 LUBRICATING  WARNING ‡ Apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.
Page 225 24. SERVICE PROCEDURE 3. Front drive shaft (3 points) 4. Rear drive shaft (3 points) 5. Upper drive shaft (3 points) 6. Parking brake linkage (6 points) 7. Torque converter mount trunnion (1 point) 3-70...
Page 226 8. Fan pulley (1 point) 9. Tension pulley (2 points) 24.8.4 CHECK TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked. 24.8.5 CLEAN FUEL STRAINER 1. Remove plug 1, then remove spring together with strainer.
Page 227 24. SERVICE PROCEDURE 24.8.7 REPLACE CORROSION RESISTOR CARTRIDGE 1. Open the engine side cover located on the right of the engine hood. 2. Screw in valve 1 at the side of the corrosion resistor. 3. Using the filter wrench provided, remove cartridge 2 by turning it counterclockwise.
Page 228 24. SERVICE PROCEDURE 24.9 EVERY 2000 HOURS SERVICE  WARNING Be sure to put a warning tag on work equipment control levers Maintenance for every 50, 100, 250, 500 and 1000 hours should be carried out at the same time. 24.9.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT ...
Page 229 24. SERVICE PROCEDURE 8. Remove mounting bolts 5 of the 3 filter covers 4 at the top of the tank, then remove the covers. When doing this, the cover may fly off because of the force of spring 6, so keep the cover pushed down while removing the bolts.
Page 230 24. SERVICE PROCEDURE NOTICE Never start the engine before the air has been completely bled from the piston pump. If the engine is started without the air being bled from the piston pump, the piston pump may be broken. 17. Check the oil level and add oil through oil filler port F if necessary.
Page 231 24. SERVICE PROCEDURE 24.9.2 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 232 24. SERVICE PROCEDURE 24.9.3 REPLACE HYDRAULIC TANK BREATHER ELEMENT  WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before chang- ing the oil. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it carefully.
Page 233 24. SERVICE PROCEDURE 24.9.4 CHANGE AXLE OIL  WARNING ‡ Apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.
Page 234 24. SERVICE PROCEDURE 2. Remove rear oil filler plug 1, then remove drain plug 2 to drain the oil. 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.
Page 235 6. Bleed the air from the hydraulic circuit. For details, see “24.2 WHEN REQUIRED”. For details of the procedure for bleeding air from the hydraulic circuit, please contact your Komatsu distributor. 3-80...
Page 236 (Reference: Value (a) of new machine = 40.7 ± 1.4 mm (1.6 ± 0.055 in)) ‡ If the disc wear approaches the wear limit, check the condition frequently, regardless of the maintenance interval. ‡ If the disc wear exceeds the wear limit, please contact your Komatsu distributor for check and maintenance. 3-81...
Page 237 (0.69 MPa (7 kgf/cm , 99.4 PSI)), so contact your Komatsu distributor to have the gas pressure measured or gas charged. Carry out the checks within 5 minutes of stopping the engine. If the machine is left with the engine stopped, the accumulator pres- sure will drop and it will be impossible to carry out the check.
Page 238 Komatsu distributor for repair. 24.10.3 CHECK FAN PULLEY AND TENSION PULLEY Check the pulley to see if there is any leaking grease. If any abnormality is found, ask your Komatsu distributor to repair or replace it. 24.10.4 CHECK AIRCOMPRESSOR, ADJUST Ask your Komatsu distributor to disassemble and repair or replace.
Page 239 SPECIFICATIONS...
Page 240 Normal load kg (lb) 23400 (51597) Bucket capacity (Heaped) (Spade nose with teeth) (cy.yd) 13.0 (16.8) Engine model – Komatsu SA12V140 diesel engine Engine horsepower kW (HP)/rpm 636 (853)/2000 Overall length mm (ft in) 13840 (45’ 5”) Overall height (with ROPS) mm (ft in) 5275 (17’...
Page 241 OPTIONS, ATTACHMENTS...
Page 242 Rear wiper and windwasher ‡ Car radio ‡ Fire extinguisher ‡ Tire inflation kit ‡ Joy stick steering system ‡ Auto grease system ‡ Hi-lift arm These and various other parts and attachments are available, so please contact your Komatsu distributor.
Page 243 Soft ground The speed display differs according to the tire size, so when chang- ing to optional tires, please contact your Komatsu distributor. On jobistes where there are many boulders or sharp rocks, please install tire protectors (mesh chain).
Page 244 28. HANDLING AUTO SHIFT SYSTEM 28.1 AUTOMATIC SHIFT SYSTEM 28.1.1 METHOD OF OPERATING Automatic gear shifting can be carried out in the 2nd to 3rd speed range of the 3 forward and reverse speeds depending on the travel conditions. Position a: 1st speed Position b: 2nd speed Position c: 3rd speed The range of speeds during automatic gear shifting is deter-...
Page 245 28. HANDLING AUTO SHIFT SYSTEM 28.2 PRECAUTIONS WHEN CHANGING DIRECTION  WARNING ‡ When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so be particularly careful when changing direction to travel in reverse.
Page 246 28. HANDLING AUTO SHIFT SYSTEM F↔R Control for change of travel direction between FORWARD and REVERSE (In the case of manual shift transmission) Gear speed Gear speed (Position of lever) at change of (Position of lever) travel direction (Command from controller) at change of travel Engine direction...
Page 247 28. HANDLING AUTO SHIFT SYSTEM 2. Control for shifting gear down at high travel speed Shifting the gear down at high travel speed will be lowered the durability of the transmission. If you shift down the gear at a high travel speed, the warning buzzer sounds for 3 seconds (rapid intermittent sound) and the controller controls the gear shifting down operation to maintain the durability according to the following table.
Page 248 29. HANDLING JOYSTICK STEERING SYSTEM To ensure that you operate the joystick steering safely and efficiently, please read this section before using it. 29.1 EXPLANATION OF COMPONENTS 1. Joystick: Converts the displacement of the steering lever into voltage and controls steering according to the operation of the F-N-R button.
Page 249 29. HANDLING JOYSTICK STEERING SYSTEM 29.2 STRUCTURE AND FUNCTION OF JOYSTICK STEERING If the joystick ON/OFF switch is turned ON, electric current flows to the joystick controller and makes it possible to operate the steering with the joystick. In addition, the directional (forward or reverse) operation of the transmission can also be carried out from the directional lever by operating the F-N-R button on the top of the joystick.
Page 250 29. HANDLING JOYSTICK STEERING SYSTEM 1) Change the transmission to the manual mode (ON/OFF) with the manual switch (push-button switch). When the switch is pressed once, the pilot lamp lights up and the system is turned ON; when the switch is pressed again, the pilot lamp goes out and the system is switched OFF.
Page 251 29. HANDLING JOYSTICK STEERING SYSTEM 2. Work with joystick and steering wheel ¤ CAUTION Because of the neutral interlock circuit, the forward and reverse directions of the transmission cannot be changed over (from forward/reverse lever to F/N/R button of the joystick when the joystick ON/OFF switch is on, and from F/N/R button of the joystick to forward/reverse lever when the joystick ON/OFF switch is off) if the forward/reverse lever and F/N/R button of...
Page 252 29. HANDLING JOYSTICK STEERING SYSTEM 29.3 OPERATION METHOD OF JOYSTICK STEERING SYSTEM ¤ CAUTION When operation with joystick lever 1, always adjust the angle of the steering wheel so that it is possible to see the F-N-R display (LED) on the left of the machine monitor. The illuminance of the LED changes as the small lamp is turned ON and OFF.
Page 253 29. HANDLING JOYSTICK STEERING SYSTEM 6. If joystick lever 1 is turned to the right, the vehicle turns to the right, and if the joystick lever is turned to the left, the vehicle turns to the left. The more sharply the joystick is turned, the more quickly the vehicle turns.
Page 254 ‡ Before starting the operation of the vehicle again, find out and repair the troubled part and confirm that the function is normal. For the troubleshooting and repair, please contact your Komatsu distributor. ‡ Never operate the vehicle before it is repaired completely. ‡...
Page 255 29. HANDLING JOYSTICK STEERING SYSTEM 29.5 ADJUSTMENT OF JOYSTICK CONSOLE ¤ WARNING ‡ When adjusting, park the vehicle on a level and safe place. ‡ Adjust before starting operation or when the operator changed. ‡ Before adjusting the console, adjust the operator's seat so that the operator can press the brake pedal fully with his back fitted to the seat back.
Page 256 29. HANDLING JOYSTICK STEERING SYSTEM 29.6 ADJUSTMENT OPERATOR’S SEAT 29.6.1 ADJUSTMENT OF SEAT ¤ WARNING ‡ Park the machine in a safe place and stop the engine when carrying out adjustment of the operator’s seat. ‡ Adjust the seat before starting operations or when changing operators.
Page 257 29. HANDLING JOYSTICK STEERING SYSTEM F: Adjusting height of headrest Move the headrest up and down to the desired height. The adjustment range is 50 mm (2.0 in). G: Adjusting headrest angle Rotate the headrest to the front or rear. H: Adjusting angle of armrest Adjust the angle of the armrest by rotating knob 5.
Page 258 30. MAIN MONITOR FAILURE DISPLAY If an error code is displayed on the main monitor portion (normally the speedometer display) of the machine monitor, follow the corresponding table when carrying out the selfdiagnostic troubleshooting below. 30.1 MAIN MONITOR FAILURE DISPLAY (Contents of operator’s actions against each error code) 5-18...
Page 259 30. MAIN MONITOR FAILURE DISPLAY 30.2 ERROR CODES LIST INDICATED ON MAIN MONITOR TRANSMISSION CONTROL SYSTEM Auto/manual transmission control system Problem system Error Code Item Short circuit Disconnection Back-up lamp relay ﬁ ﬁ None – – F Sol. ﬁ ﬁ R Sol.
Page 260 30. MAIN MONITOR FAILURE DISPLAY JOYSTICK CONTROL SYSTEM (Including joystick unit and machine body harness system) Problem system Error Code Item Short circuit Disconnection Joystick caution relay ﬁ (*1) Steering R (right) Sol (Detected when power is ﬁ ﬁ output) Steering L (left) Sol (Detected when power is ﬁ...
Page 261 3. Turn the starting switch ON and check that lamp 5 on the monitor panel lights up. Lighting: Normal Flashing: There is not sufficient grease in the grease pump. If the lamp still flashes after grease pump is filled with grease, consult your Komatsu distributor. 5-21...
Page 262 31. HANDLING AUTO-GREASING SYSTEM 31.1 METHOD OF OPERATING AUTO-GREASING SYSTEM 1. If the starting switch of the vehicle is turned ON, this system automatically starts the operation. 2. Auto-greasing switch 1 If the auto-greasing switch 1 is pressed, the grease pump is operated, regardless of the time count.
Page 263 31. HANDLING AUTO-GREASING SYSTEM 3. Method of bleeding air from pressure switch This work shall be performed by two persons. 1) Open transmission inspection cover 5 at the rear of the cab. One person removes pressure switch 7 from block 6, then stays there.
Page 264 31. HANDLING AUTO-GREASING SYSTEM 6. Check of supply line pressure Check grease pump pressure gauge B and supply grease line pressure gauge C. Supply grease line pressure gauge Normal value: 20.6 MPa (210 kgf/cm , 2982 PSI) Grease pump pressure gauge Normal value: 2.06 MPa (21 kgf/cm , 298.2 PSI) 7.
Page 265 31. HANDLING AUTO-GREASING SYSTEM 8. Adjustment of greasing rate and injector ‡ 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. ‡...
Page 266 31. HANDLING AUTO-GREASING SYSTEM Greasing points (Front frame and loader linkage) 1. Bucket hinge 2. Bucket link (front) 3. Bucket link (rear) 4. Bucket cylinder rod 6. Tilt lever (center) 7. Boom cylinder rod 5-26...
Page 267 31. HANDLING AUTO-GREASING SYSTEM Greasing points (Rear frame) 5. Bucket cylinder bottom 8. Boom cylinder bottom 9. Boom pivot 10. Center hinge pin (upper) 11. Steering cylinder bottom 12. Center support 13. Center hinge pin (lower) 14. Rear axle support (front) 15.
Page 268 31. HANDLING AUTO-GREASING SYSTEM 31.3 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 269 31. 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 270 31. HANDLING AUTO-GREASING SYSTEM 31.4 METHOD OF SETTING TIMER ‡ The timer is installed to control the greasing interval of the auto- grease system. ‡ The timer is installed in box 1 at the rear of the operator’s seat. ‡ The greasing interval can be changed freely according to the following table with the blue dial of the timer.
Page 271 31. 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 this dial to position 8 (60 seconds).) Position of switch Operating time of pump (sec) 22.5...
Page 272 32. AIR CONDITIONER 32.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL 1. FAN SWITCH This can be used to adjust the air flow to four stages. This switch also acts as the main switch for the air conditioner. When the switch is pressed, the indicator lamp above the switch lights up to indicate the air flow.
Page 273 32. AIR CONDITIONER 4. FRESH/RECIRC SELECTOR SWITCH This switch is used to select between recirculating the air inside the cab or taking in fresh air from outside. When the RECIRC position is selected, the indicator lamp above the switch lights up. When the switch is pressed again, the indicator lamp goes out, and fresh air is taken in.
Page 274 32. AIR CONDITIONER 32.2 METHOD OF OPERATION Switch Air conditioner Temperature FRESH/RECIRC Vent mode Condition switch switch control switch switch selector switch of use Rapid All blue RECIRC FACE Cooling More than Normal HI-LO FRESH FACE half are blue More than Dehumidifying, heating HI-LO FRESH...
Page 275 33. AM/FM CAR RADIO 33.1 EXPLANATION OF COMPONENTS 1. POWER SWITCH/VOLUME CONTROL KNOB Push this knob to switch the radio on. Turn the knob clockwise to increase the sound, and counterclockwise to reduce it. 2. TONE CONTROL KNOB (TONE) Turn this knob clockwise from the center position to emphasize the high sounds, and counterclockwise to emphasize the low sounds.
Page 276 33. AM/FM CAR RADIO 4. CLK(clock button)/(displaying frequency) When this button is pressed, the display changes to clock. When pressed again, frequency is displayed. 5. ME The preset stations are called in turn by pressing this button. When the desired broadcasting station is reached, press this button again, and it stops at that station.
Page 277 33. AM/FM CAR RADIO 33.2 METHOD OF USE 1. Turn the ignition key to ACC or ON, and then turn the power 1 of the radio to ON. 2. Set the “BAND” switch 2 to MW(AM) or FM. 3. Select the broadcasting station using the preset switch or the tuning switch 3.
Page 278 33. AM/FM CAR RADIO METHOD OF AUTOMATIC MEMORY The receiptable broadcasting station at your site are called in turn by pressing “ME” button for 2 seconds and they are automati- cally memorized in the preset memory. AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO When the radio wave of receiving FM stereo signal is weak (such as when receiving at the area or the mountainous region that are far from the broadcasting stations), stereo is switched to monaural...
Page 279 34. AM/FM RADIO-CASSETTE STEREO 34.1 EXPLANATION OF COMPONENTS 1. POWER SWITCH/VOLUME CONTROL KNOB Turn this knob clockwise until it clicks, and the power is turned on. Turn it further to increase the sound. 2. TONE CONTROL KNOB Adjust the tone of the sound by turning this knob. 3.
Page 280 34. AM/FM RADIO-CASSETTE STEREO 4. TREBLE CONTROL KNOB Slide this knob to the right to enhance high frequency sound and to the left to suppress high frequency sound. 5. EJECT BUTTON Press this button to eject the cassette tape. 6. CASSETTE DOOR Insert a cassette tape with the exposed magnetic tape side facing to the right.
Page 281 34. AM/FM RADIO-CASSETTE STEREO 10. SEEK SWITCH When this SEEK button is pressed, the system automatically searches for a receivable station, and automatically stops search- ing once a station is picked up. 11. LOUD BUTTON This button is used to operate the system at a lower sound volume but with enhanced bass and treble sound.
Page 282 34. AM/FM RADIO-CASSETTE STEREO 16. PRESET SWITCH (IN RADIO MODE) One station each in the FM1, FM2, FM3 and MW (AM) bands, respectively, can be preset for buttons 1 to 6 shown at right. (Refer to the section “Presetting to selected stations”.) 17.
Page 283 34. AM/FM RADIO-CASSETTE STEREO 34.2 OPERATION METHOD PRESETTING TO SELECTED STATIONS When listening to a preset station, select one of the AM, FM1, FM2 and FM3 bands using band select switch 1, then simply press the number key corresponding to the preset selected station. The system can memorize 6 stations in AM band and 18 stations in FM bands (FM1: 6 stations, FM2: 6 stations and FM3: 6 stations).
Page 284 34. AM/FM RADIO-CASSETTE STEREO RECEIVING RADIO BROADCASTS 1. Turn ON the ignition key, then turn on power switch 1 of the car stereo. 2. Select either AM or FM band with the band select switch 2. 3. Tune to the desired station using the preset switch or tuner switch 3.
Page 285 34. AM/FM RADIO-CASSETTE STEREO ADJUSTING TIME 1. Turn on the ignition key, then turn on the power switch of the car stereo. If the frequency is displayed on the display, change the display to the clock using the display changeover switch. 2.
Page 286 34. AM/FM RADIO-CASSETTE STEREO WHEN PLAYING A CASSETTE TAPE 1. Turn on the ignition key, then turn on the power switch of the car stereo. 2. Insert your cassette tape in the cassette door with the exposed tape on the right side. The tape will start playing automatically. If the tape running direction indication is >, the upper channel of the tape is being played and if <...
Page 287 34. AM/FM RADIO-CASSETTE STEREO 34.3 PRECAUTIONS WHEN USING ‡ Retract the antenna when traveling in places with low overhead height. ‡ For safety reasons, when operating, keep the sound to a level where you can enjoy the sound but still hear the sound from outside the vehicle.
Page 288 35. HANDLING AJSS (ADVANCED JOYSTICK STEERING SYSTEM) Always read this section before using the E.C.S.S. in order to enable you to use it safely and effectively. 35.1 EXPLANATION OF COMPONENTS 1. Direction selector switch 8. Shift down switch 2. Armrest angle adjustment knob 9.
Page 289 35. HANDLING AJSS (ADVANCED JOYSTICK STEERING SYSTEM) 1. When selecting the method for shifting the transmission gear, press transmission autoshift/manual selector switch q (push button switch) to switch it ON or OFF. When the switch is pressed once, pilot lamp w lights up and the system is turned ON;...
Page 290 35. HANDLING AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL FOR SHIFTING GEAR DOWN AT HIGH TRAVEL SPEED If it is attempted to switch between FORWARD and REVERSE when the machine is traveling at high speed, if the travel speed and engine speed are in area I in the chart on the right, the alarm buzzer will sound for 3 seconds (rapid intermittent sound).
Page 291 35. HANDLING AJSS (ADVANCED JOYSTICK STEERING SYSTEM) ‡ The present speed range and N are displayed on the main monitor N display. ‡ F and R are displayed on the main monitor FR display. 1. Fasten the seat belt. 2. Check that the directional switch of joystick steering lever q is at the N position and that joystick steering lever is also at the neutral position.
Page 292 35. HANDLING AJSS (ADVANCED JOYSTICK STEERING SYSTEM) 7. Use the directional selector switch on the head of joystick steering lever q to shift the direction of travel of the transmis- sion between FORWARD and REVERSE. Position F: Forward Position N: Neutral Position R: Reverse To shift the speed range, use shift up switch e or shift down switch r on the head of the joystick steering lever.
Page 293 35. HANDLING AJSS (ADVANCED JOYSTICK STEERING SYSTEM) 35.4 ADJUSTMENT OF JOYSTICK CONSOLE ¤ WARNING ‡ Stop the machine on level ground in a safe place when carrying out the adjustment. ‡ Carry out the adjustment before starting operations or when changing operator shifts.
Page 294 35. HANDLING AJSS (ADVANCED JOYSTICK STEERING SYSTEM) 35.5 ADJUSTMENT OF AIR SUSPENSION SEAT (Seat adjustment) ¤ WARNING ‡ When adjusting the operator's seat, stop the machine in a safe place. ‡ Adjust the seat before starting operations for the day or when changing operators.
Page 295 35. HANDLING AJSS (ADVANCED JOYSTICK STEERING SYSTEM) D Adjusting reclining angle Move lever q up and move the seat backrest to the front or rear. Push your back against the backrest when carrying out this adjustment. If your back is not pressing against the backrest, the backrest may suddenly spring forward.
Page 296 36. HANDLING MULTI MONITORING SYSTEM 36.1 GENERAL LOCATIONS 1 Multi display portion A Service meter ‡ Auto-leveling control system ‡ Screen selector switch 2 Level set up pilot lamp B Monitor mode switch 3 Level set up switch C Load meter mode switch 4 Auto mode pilot lamp D Maintenance mode switch 5 Auto mode switch...
Page 297 The power for the multi monitor is turned on and the display starts to show the condition of the machine. 1) The Komatsu logo is displayed. 2) After 3 seconds, the check before starting is started. The check is started for the fluid levels for 4 items: engine oil level, coolant level, fuel level, and battery electrolyte level.
Page 298 36. HANDLING MULTI MONITORING SYSTEM 5) When the check is completed and GOOD is displayed for each item, the display changes to troubleshooting for the oil maintenance 6) The specified maintenance time and the time remaining to the specified time are displayed for 4 items: engine, trans- mission, work equipment, axle.
Page 299 36. HANDLING MULTI MONITORING SYSTEM 2. When the START OK display appears, turn the starting key to the START position and start the engine. After the engine is started, the display starts to show the condi- tion of the machine. 1) The check starts for 3 pressure items: engine oil pressure, brake oil pressure, charge voltage.
Page 300 36. HANDLING MULTI MONITORING SYSTEM 6) After 5 seconds, the system changes to the monitor mode. The monitor mode is normally displayed during operation. 3. To turn off the power to the multi monitor and erase the display of the condition of the machine, turn the starting switch to the OFF position.
Page 301 36. HANDLING MULTI MONITORING SYSTEM 36.3 SWITCHING MONITOR SCREEN When the engine is started, it is possible to switch to the following 5 mode screens on the monitor mode display by keeping the panel switch pressed for more than 2 seconds. 1.
Page 302 36. HANDLING MULTI MONITORING SYSTEM 36.3.1 MONITOR MODE Monitoring is carried out after the engine is started. Normally this mode is displayed after the engine is started. To switch to the monitor mode from another mode, keep the monitor switch on the panel pressed for at least 2 seconds. The normal display item screen is shown.
Page 303 36. HANDLING MULTI MONITORING SYSTEM 36.3.2 LOAD METER MODE 1. Keep the load meter switch on the panel pressed for at least 2 seconds. Screen 1 is displayed. 2. Each time the load meter switch is kept pressed for at least 2 seconds, the screen will change.
Page 304 36. HANDLING MULTI MONITORING SYSTEM Method for carrying out calibration (0 point adjustment) Carry out calibration with the hydraulic oil temperature and engine speed at the same conditions as actually used during opera- tion (engine speed at rated speed). 1. When using aggregate value display measurement method 1) Press the load meter switch to display screen 2 (calibration) 2) Follow the instructions on the screen: “With no load, tilt bucket fully back, then raise boom.”...
Page 305 36. HANDLING MULTI MONITORING SYSTEM Method of measuring with aggregate value display It is possible to calculate the aggregate value in categories for each material being handled up to a maximum of 5 types. It is possible to change the setting for types A to E for each type of material being handled, and to record the aggregate value for each material during the operation.
Page 306 36. HANDLING MULTI MONITORING SYSTEM 5. To delete the data in aggregate value display portion 2 during operations, press the figures, sub-total switch and load meter switch together for at least 2 seconds. NOTICE When carrying out Step 5, the data will also be deleted from the storage device for the multi monitoring system.
Page 307 36. HANDLING MULTI MONITORING SYSTEM 8. To set aggregate value display portion 2 to 0.0 tons, press the figures, sub-total switch or the sub-total switch on the bucket control lever for at least 2 seconds, and print out the present production.
Page 308 36. HANDLING MULTI MONITORING SYSTEM Method using remaining display measurement It is possible to calculate the aggregate value in categories for each material being handled up to a maximum of 5 types. It is possible to change the setting for types A to E for each type of material being handled, and to record the remaining value for each material during the operation.
Page 309 36. HANDLING MULTI MONITORING SYSTEM 5. Next, set the target production amount. Press the NEXT/RENEW switch for at least 2 seconds. The alphabet in type display portion 1 will change to yellow and will flash. 6. Press the NEXT/RENEW switch lightly again. The position of the flashing display in remaining value display portion 2 will change in turn.
Page 310 36. HANDLING MULTI MONITORING SYSTEM 9. After loading the material into the bucket, tilt the bucket fully and raise the boom. The buzzer will sound, and at the same time, the load in the bucket will be displayed in load weight display portion 3. This load will be subtracted from the previous remaining value in the remaining value display portion, and the result will be displayed as the production amount.
Page 311 36. HANDLING MULTI MONITORING SYSTEM ‡ When target production will be exceeded if measured load is loaded onto dump truck 1) The value in remaining value display portion 1 is shown in red with a – mark. After 3 seconds, the display returns to the previous display and changes to yellow.
Page 312 36. HANDLING MULTI MONITORING SYSTEM When the display in remaining value display portion 1 shows 0 tons or a value close to this, the loading to the target value is completed, so press the figures, sub-total switch or the bucket control lever sub-total switch for at least 2 sec- onds and print out.
Page 313 36. HANDLING MULTI MONITORING SYSTEM 5) When using the displays in the remaining value display portion 1 and load weight display portion 2 to adjust the load in the bucket when loading the dump truck and an amount in excess of the target production is loaded, print out the data.
Page 314 36. HANDLING MULTI MONITORING SYSTEM 36.3.3 MAINTENANCE MODE 1. Press the maintenance switch on the panel for at least 2 seconds. Screen 1 is displayed. 2. Each time the maintenance switch is pressed for at least 2 seconds, the screen will change. Method of resetting remaining time When changing the oil or replacing the filter, reset the remaining time as follows.
Page 315 36. HANDLING MULTI MONITORING SYSTEM 2. Press the maintenance switch on the panel for at least 2 seconds and display the screen with the items which are to be reset. 3. Press the NEXT/RENEW switch for at least 2 seconds and display the Oil Maintenance screen.
Page 316 36. HANDLING MULTI MONITORING SYSTEM 5. Press the figures, sub-total switch for at least 2 seconds. The remaining time on the screen will be set to the specified time. REMARK If you reset another item by mistake, press the figures, sub-total switch for at least 2 seconds to return to the number that existed before it was reset.
Page 317 36. HANDLING MULTI MONITORING SYSTEM Method for making initial settings when auto-greasing system is installed If the auto-greasing system is installed, it is unnecessary to set the replacement intervals for the following five items: axle pivot pin, work equipment pin, steering cylinder pin, center hinge pin, and center support.
Page 318 36. HANDLING MULTI MONITORING SYSTEM 4. Press the NEXT/RENEW switch for at least 2 seconds, and carry out the same operation as in Step 3 for the next items (work equipment pin and steering cylinder pin). 5. Press the maintenance switch on the panel to display screen 4 (pin maintenance 2).
Page 319 36. HANDLING MULTI MONITORING SYSTEM 36.3.4 OIL, WATER SUPPLY MODE 1. Press the supply oil and coolant switch on the panel and display screen 1. 2. Each time the supply oil and coolant is pressed for at least 2 seconds, the screen will change. Method of setting refill oil, water amount 1.
Page 320 36. HANDLING MULTI MONITORING SYSTEM 3. Move the flashing display to the item which is to be changed. ‡ Press the NEXT/RENEW switch for at least 2 seconds. The flashing display will move to the left (horizontally). ‡ Press the supply oil and coolant switch for at least 2 seconds. The flashing display will move to the next item (vertically).
Page 321 36. HANDLING MULTI MONITORING SYSTEM 4. Press the figures, sub-total switch. The numerals in the flashing display will change in turn. 5. If any other item is to be changed, repeat Steps 3 and 4. To change the screen display, press the supply oil and coolant switch for at least 2 seconds.
Page 322 36. HANDLING MULTI MONITORING SYSTEM 36.3.5 WORKING RECORD MODE 1. Press the working record switch on the panel for at least 2 seconds to display screen 1. 2. Each time the working record switch pressed for at least 2 seconds, the screen will change. Method of printing out working record 1.
Page 323 36. HANDLING MULTI MONITORING SYSTEM 2. Press the figures, sub-total switch or bucket control lever sub- total switch to print out the operation record. After printing out, clear the oil, water supply set data, number of loads, total aggregate weight, and abnormality occurrence items. The following is an example of an operation record print out.
Page 324 36. HANDLING MULTI MONITORING SYSTEM METHOD OF SETTING DATE, TIME, SERIAL NUMBER 1. Press the working record switch on the panel for at least 2 seconds to display screen 2. 2. Press the NEXT/RENEW switch for at least 2 seconds. The color of the last digit of the serial number will change to yellow and the display will flash.
Page 325 36. HANDLING MULTI MONITORING SYSTEM Method of setting serial number 1) Press the working record switch and move the flashing display to the position of the serial number. 2) Press the NEXT/RENEW switch for at least 2 seconds. The flashing display will move to the left (horizontally). 3) Press the figures, sub-total switch.
Page 326 36. HANDLING MULTI MONITORING SYSTEM ‡ Method of setting date, time 1) Press the working record switch and move the flashing display to the position to be set. 2) Press the figures, sub-total switch. The numerals in the flashing display will change in turn. 3) When all the settings have been completed, press the NEXT/ RENEW switch for at least 2 seconds.
Page 327 36. HANDLING MULTI MONITORING SYSTEM METHOD OF SELECTING LOAD METER PRINT 1. Press the working record switch on the panel for at least 2 seconds to display screen 3. 2. Press the NEXT/RENEW switch for at least 2 seconds. The mode selection display (A or B) will change to yellow. 3.
Page 328 36. HANDLING MULTI MONITORING SYSTEM CONCEPT OF WORKING TIME Start of working time: Time when engine rotation starts after previous print processing. Or time of previous print processing during engine operation. End of working time: Time of print processing during engine operation, or time when engine is stopped when carrying out print processing with starting switch ON after stopping the...
Page 329 36. HANDLING MULTI MONITORING SYSTEM 36.4 DISPLAY WHEN THERE IS ABNORMALITY If any abnormality occurs in the machine, the display automati- cally switches to the abnormal display, and the warning lamp inside the main monitor is actuated according to the seriousness of the abnormality.
Page 330 36. HANDLING MULTI MONITORING SYSTEM ABNORMALITY DISPLAY TABLE Warning Item Abnormality display Lamp Buzzer Check Caution ﬁ Engine oil level NOT GOOD ﬁ Coolant level NOT GOOD ﬁ Battery electrolyte level NOT GOOD ﬁ Fuel level NOT GOOD ﬁ Engine oil pressure line OPEN CIR or SHRT CIR ﬁ...
Page 331 36. HANDLING MULTI MONITORING SYSTEM 36.5 HANDLING PRINTER 36.5.1 GENERAL LOCATIONS 1. Select switch 6. Paper inspection window 2. Pilot lamp 7. Power switch 3. Error lamp 8. On-line lamp 4. Cutter 9. Paper end lamp 5. Paper replacement lid 10.
Page 332 36. HANDLING MULTI MONITORING SYSTEM 36.5.2 EXPLANATION OF COMPONENTS 1. PILOT LAMP (GREEN) This lights up when the printer power is switched ON. 2. ON-LINE LAMP (GREEN) This lights up when the printer is on line. It is possible to receive and print out data. 3.
Page 333 36. HANDLING MULTI MONITORING SYSTEM 36.5.3 SELF TEST If the power is turned on when the FEED switch is being pressed, the printer will enter the self-test mode, so check the condition of the print out. The printer will print out the internal CG ROM data. In JIS 6220 mode, level 1 and level 2 Japanese characters will be printed out.
Page 334 36. HANDLING MULTI MONITORING SYSTEM 36.6 PRECAUTIONS WHEN HANDLING MULTI MONITORING SYSTEM  CAUTION ‡ Do not push the liquid crystal panel strongly or allow any- thing to hit it. ‡ Do not let water get on the equipment. If water gets inside, it will cause failure. ‡...
Page 335 37. HANDLING REMOTE POSITIONER The remote positioner system is a system to increase operating efficiency and to reduce operator fatigue. It consists of function: the lift arm remote positioner. The remote positioner system makes it possible to set the stop position for the lift arm at the desired position from the operator’s seat, and it is also provided with a modulation function to reduce the shock when stopping the lift arm.
Page 336 OFF, the pilot lamp goes out, and the system changes to the normal positioner condition. 37.3 ADJUSTING REMOTE POSITIONER When the lift arm or tilt lever has been removed or the setting does not work efficiently, please contact your Komatsu distributor for adjustment. 5-96...
Page 337 38. SOUND PACKAGE SPECIFICATION 38.1 OUTLINE OF SOUND PACKAGE 1. Hydraulic pump 2. Radiator 3. Oil cooler 4. Cooling fan 5. Hydraulic tank a: To hydraulic The engine cooling fan is driven by hydraulic pressure from the hydraulic pump; it is not driven directly by the power of the engine. The hydraulic pressure from the hydraulic pump rotates the hydrau- lic motor connected directly to the cooling fan.
Page 338 38. SOUND PACKAGE SPECIFICATION 38.2 SERVICE ITEM The cooling fan is driven by a hydraulic motor, so the following items are no longer included in the normal inspection. Items no longer needing inspection ‡ When required Replace fan belt, adjust auto-tensioner ‡...
Page 339 38. SOUND PACKAGE SPECIFICATION 38.3 DIMENSIONS Item Unit Overall length mm (ft in) 14275 (46’ 10”) Overall height (with ROPS) mm (ft in) 5275 (17’ 4”) Bucket overall height (when bucket lifted) mm (ft in) 9680 (31‘ 9”) Overall width mm (ft in) 4585 (15’...
Page 340 39. HANDLING BRAKE COOLING SYSTEM An air-cooled oil cooler is installed for the brake cooling oil (axle oil) to improve the cooling capacity. If the oil temperature goes above approx 105°C (221°F), the caution lamp flashes to warn the operator that the oil is overheated. 39.1 EXPLANATION OF COMPONENTS 39.1.1 BRAKE COOLING OIL TEMPERATURE CAUTION LAMP...
Page 341 39. HANDLING BRAKE COOLING SYSTEM 39.2 SERVICE PROCEDURE 39.2.1 WHEN REQUIRED 39.2.1.1 CHECK AXLE OIL LEVEL, ADD OIL  WARNING ‡ When checking the oil level, apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡...
Page 342 39. HANDLING BRAKE COOLING SYSTEM 39.2.1.2 CLEAN BRAKE COOLING OIL COOLER FINS Clean the fins if there is any mud or dirt stuck to the brake cooling oil cooler. Blow off the dirt, dust or tree leaves clogging or sticking to the fins with compressed air.
Page 343 39. HANDLING BRAKE COOLING SYSTEM 39.2.3 EVERY 2000 HOURS SERVICE 39.2.3.1 REPLACE AXLE OIL AND BRAKE COOLING OIL FILTER CARTRIDGE The replacement interval for the axle oil is 2000 hours for standard operations, but if the brakes are used frequently or the brakes squeal, reduce the oil change interval.
Page 344 39. HANDLING BRAKE COOLING SYSTEM 2. Remove rear oil filler plug 1, then remove drain plug 2 to drain the oil. 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.
Page 345 40. HANDLING 55°C (131°F) SPECIFICATION In addition to the standard oil cooler, an air-cooled oil cooler is also installed to improve the cooling capacity for the hydraulic oil and torque converter oil. 40.1 SERVICE PROCEDURE 40.1.1 WHEN REQUIRED 40.1.1.1 CLEAN OIL COOLER FINS Clean the oil cooler if mud or dirt is stuck to it.
Page 346 41. SERVICE CENTER Adding or draining oil or coolant, in addition to oil sampling can be carried out in a centralized manner at this service center. REMARK A pump for filling and draining is required to do the work in this service center.
Page 347 41. SERVICE CENTER 41.1 SIZE OF SCREWS USED IN SERVICE CENTER 41.1.1 SIZE OF SCREWS USED WHEN SUPPLYING FLUID OR RELEASING INTERNAL PRESSURE WHEN ADDING OR DRAINING OIL OR COOLANT. The size of the screws used when supplying fluid or releasing internal pressure when adding or draining oil or coolant is as follows.
Page 348 41. SERVICE CENTER 41.1.3 SIZE OF SCREWS AT SPARE PIPING Fittings for the piping are installed as a spare. q Spare (1) r Spare (2) Size of fittings for piping inside machine: M22 Size of fittings for piping outside machine: 1/2 – 14NPTF o Spare (3) Size of fittings for piping inside machine: M30 Size of fittings for piping outside machine: 3/4 –...
Page 349 41. SERVICE CENTER 41.2 LOCATION OF SWITCHING VALVES FOR REFILLING WITH OIL AND COOLANT AND DRAINING A switching valve is provided in the piping to fill with oil and coolant and drain them. Keep the switching valves open all the time, and close them when replacing the hoses.
Page 350 42. EMERGENCY ENGINE STOP SWITCH An emergency engine stop switch is provided in the operator’s cab and two other spots on the machine’s periphery (3 spots total). If any one of them is pressed, the engine stops. Use this switch only in emergency, and for normal starting and stopping of the engine, use the engine starting switch.
Page 351 43. HANDLING BATTERY DISCONNECTOR SWITCH AND STARTING MOTOR DISCONNECTOR SWITCH When battery disconnector switch q is turned OFF, the battery ground circuit is shut off, and the electric circuit for the whole machine is shut off. When starting motor disconnector switch w is turned OFF, the power supply circuit (24V) to the starting motor is shut off.
Page 352 43. HANDLING BATTERY DISCONNECTOR SWITCH AND STARTING MOTOR DISCONNECTOR SWITCH 43.2 HANDLING  WARNING ‡ Do not operate the battery disconnector switch or starting motor disconnector switch when the starting switch is at the ON position. ‡ Do not turn the battery disconnector switch or starting motor disconnector switch to the OFF position when the engine is running or immediately after stopping the engine.
Page 353 44. HANDLING STARTING AID CONNECTOR 44.1 STARTING ENGINE WHEN USING STARTING AID CONNECTOR A starting aid connector that conforms to SAE J1283 is available as an option for this machine. The starting aid connector is at the side of the battery box on the left side of the machine.
Page 354 45. CENTRALIZED BREATHER The breathers for the damper case, rear axle housing, front axle housing, and transmission are centralized and installed at the rear right under the cab floor. REMARK On the standard machine, they are installed to each component, but in this case, to make maintenance easier, they are centralized and installed at the rear right under the cab floor.
Page 355 46. HYDRAULIC OIL LEVEL WARNING DISPLAY q Hydraulic oil level warning lamp If the oil level in the hydraulic tank goes down while the machine is being operated, the hydraulic oil level warning lamp lights up, the central warning lamp (CAUTION) on the machine monitor flashes, and at the same time, the alarm buzzer sounds intermittently.

Komatsu Avance Loader WA900-3 Operation & Maintenance Manual

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