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Komatsu WA480-8 Operation & Maintenance Manual

Komatsu WA480-8 Operation & Maintenance Manual

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Operation & Maintenance

Manual

DANGER

Incorrect operation and maintenance of this machine

may be hazardous and cause injuries. The operator and

maintenance personnel must read this manual before

commencing operation or maintenance. Keep this

manual within reach at all times and ensure that

operating personnel read it at regular intervals.

© 2018 KOMATSU

All Rights Reserved

Printed in Europe 07-2018

WA480

WHEEL LOADER

SERIAL NUMBERS H53051 AND UP

1000010 AND UP

ORIGINAL INSTRUCTIONS

VENAM51500

-8

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Summary of Contents for Komatsu WA480-8

Page 1 The operator and maintenance personnel must read this manual before commencing operation or maintenance. Keep this manual within reach at all times and ensure that operating personnel read it at regular intervals. © 2018 KOMATSU All Rights Reserved Printed in Europe 07-2018...
Page 3 Komatsu or Ko- matsu approved rebuilt parts or assemblies or others parts of equivalent quality, and that the engine be serviced by an authorized Komatsu distribu- tor. Failure to follow these recommendations could result in ineffective serv- ice, damage to the product or safety risks (including personal injury or death).
Page 4: Eu Directives
Keep it in the storage door (1) beside the shoes box on the left side of the operator's seat. If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement.
Page 5 The transmitter unit must be spatially separated from the vehicle’s electronic system. • Make sure when installing the antenna that this is installed correctly with good earth connection between antenna and vehicle mass. Also observe Komatsu and manufacturer’s installation instructions for wiring, installation and maximum permit- ted power consumption.
Page 6: Komatsu Machine Operator Privacy Policy
Belgium, with registered office at 1800 Vilvoorde, Belgium, Mechelsesteenweg 586, registered in Brussels un- der number RPR/CER(0)404.968.268 ("Komatsu Europe", together with the other Komatsu subsidiaries in the EEA referred to as "we" or "us"). Komatsu Europe acts as Komatsu's representative in the EU with respect to MMS.
Page 7 KOMATSU MACHINE OPERATOR PRIVACY POLICY • pictures, videos and sound recordings 4. Why is your personal data processed? When you use Komatsu machines equipped with MMS, your personal data are processed for the following rea- sons: (a) Safety and security (b) Warranty...
Page 8 (30) days after having received the request. If you have any complaint regarding the processing of your personal data by Komatsu or Komatsu Europe via MMS, you may always contact us via the e-mail address mentioned in the first paragraph of this clause. If you...
Page 9: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 10: Noise Emission Levels
NOISE EMISSION LEVELS FOREWORD NOISE EMISSION LEVELS Two signs are attached to the machine that state the noise level produced. • Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A weighted emission sound pressure level at the operator's position is 2.5 dB, in accordance with ISO 11201.
Page 11: Vibration Level
FOREWORD VIBRATION LEVEL VIBRATION LEVEL When used for its intended purpose, levels of vibration for the earth working machine transmitted from the oper- ator’s seat are lower or equal to the test vibrations for the relative machinery class in compliance with ISO 7096. The actual acceleration value of the upper limbs is less than 2.5 m/s .
Page 12: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Digging work • Leveling work • Dozing work • Loading work For details of the work procedure, see “RECOMMENDED APPLICATIONS (3-206)”.
Page 13 FOREWORD INTRODUCTION This machine maintains a proximity visibility of a height of 1.2 m and 1.5 m at a 1 m away from the outside sur- face of the machine, and a visibility for a radius of 12 m. Height to evaluate the proximity visibility Front side Left-hand side Right-hand side...
Page 14 INTRODUCTION FOREWORD To assist with job site organisation during use of this machine, a visibility map is provided that shows an approxi- mation of any masking to visibility between the 1 m rectangular boundary and the 12 m test circle. Based upon the information supplied in the visibility map the site operator may wish to provide additional meas- ures where it is felt necessary or provide additional instruction to personnel.
Page 15: Engine Technology To Conform Exhaust Gas Emission
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union. • Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process to burn the soot is performed automatically to keep the filtering performance of KDPF high.
Page 16: Product Information
PRODUCT INFORMATION FOREWORD PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE This is located at the center of the front frame on the right side of the machine.
Page 17: Rops/Fops Serial Plate Location
ROPS/FOPS SERIAL PLATE LOCATION AXLE SERIAL PLATE LOCATION This plate is located on the right of front axle and on the left of rear axle. PRODUCED BY KOMATSU GERMANY GmbH, HANNOVER FEDERAL REPUBLIC OF GERMANY FOR Komatsu Ltd.,Tokyo,Japan MODEL PART NO.
Page 18: Seat Plate Location
SERVICE METER LOCATION It is at the center bottom of the machine monitor. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturer name Komatsu Germany GmbH Address Hanomag Strasse 9 30449 Hannover Germany 1-16...
Page 19 FOREWORD PRODUCT INFORMATION Distributor name Address Phone/Fax Service personnel 1-17...
Page 20: Declaration Of Conformity
DECLARATION OF CONFORMITY FOREWORD DECLARATION OF CONFORMITY The manufacturer: Komatsu Germany GmbH Hanomag Straße 9 30449 Hannover Germany Declares that this machine: WA480-8* Fulfils all the relevant provisions of following EC Directives: Machine Directive 2006/42/EC Electro Magnetic Compatibility Directive 2014/30/EU...
Page 21: Retrofitting By Third-Party Suppliers
In the event of tools (e.g. loading shovels) being retrofitted by a third-party supplier, the technical specifications of the manufacturer must be taken into account. For this purpose, or for further information, please be sure to consult Komatsu or your local Komatsu dealer. 1-19...
Page 22: Explanation Of Acronyms
EXPLANATION OF ACRONYMS FOREWORD EXPLANATION OF ACRONYMS Acronyms Stand for: KDPF Komatsu Diesel Particulate Filter KVGT Komatsu Variable Geometry Turbo KCCV Komatsu Closed Crankcase Ventilation Selective Catalytic Reduction Diesel Exhaust Fluid ECSS Electrically Controlled Suspension System 1-20...
Page 23: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 EU DIRECTIVES ..........................1-2 KOMATSU MACHINE OPERATOR PRIVACY POLICY ................1-4 SAFETY INFORMATION .......................... 1-7 NOISE EMISSION LEVELS ........................1-8 VIBRATION LEVEL........................... 1-9 INTRODUCTION ............................ 1-10 MAIN USE OF MACHINE ........................ 1-10 DIRECTIONS OF MACHINE......................
Page 24 OTHER TROUBLE......................... 3-250 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................
Page 25 EVERY 8000 HOURS MAINTENANCE ................... 4-76 EVERY 9000 HOURS MAINTENANCE ................... 4-77 SPECIFICATIONS ............................5-1 SPECIFICATIONS ............................ 5-2 SPECIFICATIONS: WA480-8......................5-2 ATTACHMENTS AND OPTIONS ........................6-1 BUCKET AND TIRE SELECTION......................6-2 HANDLE MULTIFUNCTION MONO-LEVER ..................... 6-3 EXPLANATION OF EQUIPMENT ON MULTIFUNCTION MONO-LEVER.......... 6-3 MULTIFUNCTION MONO-LEVER .....................
Page 26 CONSUMABLE PARTS LIST ......................7-3 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-4 LUBRICATION CHART ........................7-4 METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-8 INDEX................................8-1 1-24...
Page 27: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
Page 28: Safety Labels
If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...
Page 29: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS...
Page 30 SAFETY LABELS SAFETY (1) Caution before operating (7) Parking brake emergency release valve (2) Caution when leaving operator's seat (8) Caution for high-temperature coolant (3) Caution when traveling in reverse (9) Caution for high temperature oil and hydraulic oil (4) Caution for electric cables (10) Caution for handling battery cable (5) Prohibition of trespassing (11) Caution for handling battery...
Page 31: Contents Of Safety Labels
SAFETY SAFETY LABELS (13) Prohibition of getting on or off fender (21) Emergency escape (14) Caution while engine is running (22) Caution for blast site (15) Caution for nearing machine (Machines equipped with KOMTRAX) (16) Prohibition of entering beneath work equipment (23) Caution when traveling in reverse (17) Caution for modification of ROPS/FOPS (Machine with rearview camera)
Page 32 SAFETY LABELS SAFETY Caution when traveling in reverse “09802–D0880” • Sign indicates a hazard of rear working and advancing be- hind. • Read manual before operation. • To prevent SEVERE INJURY or DEATH, do the following before moving machine or its attachments: •...
Page 33 SAFETY SAFETY LABELS Caution for frame lock bar “09161-C0641” • Sign indicates a crush hazard between the articulating parts of vehicle. • Lock vehicle with lock bar to avoid movement during main- tenance and transportation. Parking brake emergency release valve “421-93-68291”...
Page 34 SAFETY LABELS SAFETY Caution for high temperature oil and hydraulic oil “09653-A0641” • Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot. • Allow radiator or hydraulic tank to cool before removing cap.
Page 35 SAFETY SAFETY LABELS Prohibition of getting on or off fender “09805-C0481” • Sign indicates a hazard of falling. • Do not stand on this place here. Caution while engine is running “09667-A0880” • Sign indicates a hazard of rotating parts, such as belt. •...
Page 36 Any modification is prohibited. • ROPS or FOPS may provide less protection if it has been structurally damaged or involved roll-over. Con- sult Komatsu Distributor in that case. • Always wear seat belt when moving. Prohibition of start by short-circuiting “09842-A0642”...
Page 37 SAFETY SAFETY LABELS Caution for hot exhaust pipe “09817-A0753” • Sign indicates a burn hazard from touching heated parts, exhaust pipe and body during or right after operation. • Never touch when hot. Caution for high-pressure common rail “6271-81-2981” • Do not open high pressure fuel system with engine run- ning.
Page 38 SAFETY LABELS SAFETY Caution when traveling in reverse (Machine with rearview camera) “09833-C0881” • When backing up, rear of machine is displayed on monitor. Before moving, look back and at mirror and monitor to con- firm that no one is rear of machine. •...
Page 39 SAFETY SAFETY LABELS Caution for handling seat belt “09848-A0480” • Always use seat belt when operating the machine to re- duce risk of injury or death in case of a roll-over. • Always check for damage or wear of the seat belt, damage of the connecting brackets, and tightness of bolts.
Page 40: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 41 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical compo- nents.
Page 42: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY PRECAUTIONS TO PREVENT FIRE ACTIONS IF FIRE OCCURS • Turn the starting switch to OFF position, and stop the engine. • Use the handrails and steps to escape from the machine. •...
Page 43: Precautions When Getting On Or Off Machine
Fire around the machine due to highly heated exhaust gas This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF). KDPF is a device to purify the soot in the exhaust gas. Exhaust gas temperature may increase during the purifi- cation process (regeneration).
Page 44 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • Do not try to get on a tire from the step in the rear side of the machine or the step beside the cab. • Do not get on or off the machine with tools in your hand. NO JUMPING ON OR OFF MACHINE Getting on or off the moving machine can cause serious personal injury or death.
Page 45: Do Not Get Caught
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • Before leaving the machine, set the machine to the straight travel condition, then be sure to lower the work equipment to the ground. Press the work equipment lock switch (1) to lock the work equipment (the pilot lamp lights up).
Page 46: Precautions Related To Protective Structures
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
Page 47: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 48 PRECAUTIONS FOR OPERATION SAFETY Voltage of Cables Safety Distance 154000 V Min. 5 m 187000 V Min. 6 m 275000 V Min. 7 m 500000 V Min. 11 m • To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera- tor's seat, and be careful not to touch the chassis with any exposed part of your body.
Page 49: Start Engine
Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. START ENGINE USE WARNING TAGS If there is a “DANGER! Do NOT operate!”...
Page 50 PRECAUTIONS FOR OPERATION SAFETY • Check the coolant level, fuel level, DEF level, and oil level in engine oil pan, check for clogging of the air cleaner, and check for damage to the electric wiring. • Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake pedal, and check that the pedals work properly.
Page 51: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cables. • When connecting a normal machine to a failed machine with the jumper cables, always use the normal machine with the same battery voltage as the failed machine.
Page 52 PRECAUTIONS FOR OPERATION SAFETY • Prohibit other personnel to get on the machine. • If there are any persons in the area around the machine, there is danger that they may be hit or caught by the ma- chine, and this may lead to serious personal injury or death.
Page 53 SAFETY PRECAUTIONS FOR OPERATION • If you drive the machine at high speed continuously for a long time, the tires will overheat and the internal pressure will become abnormally high. This may cause the tires to burst. If a tire bursts, it produces a large destructive force, and this may cause serious injury or death.
Page 54 PRECAUTIONS FOR OPERATION SAFETY • When the bucket is loaded, direct the bucket toward the hill top both in uphill and downhill travel. When driving the machine with the bucket directing downhill, it is liable to tip over and is dangerous. METHOD OF USING BRAKES •...
Page 55 SAFETY PRECAUTIONS FOR OPERATION PROHIBITED OPERATIONS If the machine tips over or falls, or the ground at the working point collapses, it may lead to serious personal injury or death. Always observe the following. • Do not dig the work face under an overhangs. There is a danger that the work face will collapse.
Page 56: Precautions For Transportation
• This machine needs to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. • Lock the frame with the frame lock bar to prevent the machine from articulating.
Page 57: Towing And Being Towed
SAFETY PRECAUTIONS FOR OPERATION • Always use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough to provide a safe loading slope. Take suitable steps to prevent the ramps from moving out of position or coming off. (1) Chocks (2) Ramp (3) Width of ramps: Same width as tires...
Page 58: Precautions For Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the “DAN- GER! Do NOT operate!” warning tag. If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 59 END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death.
Page 60 If the automatic active regeneration of KDPF starts during maintenance work, surroundings of KDPF become high temperature. When performing maintenance work, perform regeneration disable of KDPF according to “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-130)”. • Lower the work equipment to the ground and press work equipment lock switch (1) to lock the work equipment (pilot lamp lights up) and prevent it from moving.
Page 61 SAFETY PRECAUTIONS FOR MAINTENANCE • Set parking brake switch (2) to ON (operation) position (A) to apply the parking brake, then put blocks in front of and behind the tires to prevent the machine from moving. • Do not touch the control levers or steering system. If it is necessary to operate the control lever or steering system, always give a signal to your fellow workers and have them take refuge to a safe place.
Page 62: Precautions For Check And Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY • Never use concrete blocks for supports. Concrete blocks may break under even light loads. USE PROPER TOOLS Use the tools suited to the task and use them correctly. Using damaged, deformed, or low quality tools, or making improper use of the tools may cause serious personal injury or death.
Page 63 SAFETY PRECAUTIONS FOR MAINTENANCE • Do not smoke or bring any open flame close to the battery. • Hydrogen gas is generated when the battery is being charged, so remove the battery from the machine, take it to a well-ventilated place, remove the battery caps, then perform the charging.
Page 64 The oil pressure in the ECSS circuit is stored by the accu- mulator. Do not remove the ECSS piping and parts. If it is necessary to remove them, ask your Komatsu dis- tributor to perform the removal work. PRECAUTIONS FOR HIGH-PRESSURE FUEL While the engine is running, high-pressure is generated in the engine fuel piping.
Page 65 If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 66 PRECAUTIONS FOR MAINTENANCE SAFETY If any doubt exists, contact your Komatsu distributor. PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution, pay full attention to the way to dispose of waste materials. • Always drain the oil from your machine in containers. Nev- er drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, seas, or lakes.
Page 67: Tires
To ensure safety, always observe the following. • Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special tech- nology, so always ask your Komatsu distributor to perform these operations. • Use only specified tires and inflate them to the specified pressure.
Page 68: Precautions For Def
PRECAUTIONS FOR DEF SAFETY PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colourless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...
Page 69: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 70: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Bucket (8) Stepladder (2) Bell crank (9) Turn signal lamp (3) Bucket cylinder (10) Headlamp (4) Rearview mirror (11) Lift cylinder (5) Front working lamp (12) Front wheel (6) ROPS cab (13) Boom (7) Rear wheel (14) Rear working lamp...
Page 71: Controls And Gauges Names
OPERATION GENERAL VIEW (15) Rearview camera (17) Auto-greasing (16) Rear combination lamp CONTROLS AND GAUGES NAMES (1) Front switch panel (12) Cigarette lighter (2) Directional lever (13) Brightness adjustment switch of rear view monitor (3) Engine shutdown secondary switch (14) Rear view monitor (4) Hazard lamp switch (15) Bucket control lever (5) Gear speed switch...
Page 72 GENERAL VIEW OPERATION (25) Front wiper switch (28) L.H. brake pedal (26) Rear wiper switch (29) Rear heated wire glass switch (27) Steering tilt lock lever (30) Room lamp switch SWITCH PANEL R.H. switch panel (1) Transmission cut-off switch (5) Directional selector enable switch on R.H. switch panel (if equipped) (1) Transmission cut-off set switch (6) Remote positioner switch...
Page 73 OPERATION GENERAL VIEW MACHINE MONITOR EQUIPMENT NAME General view (A) LCD unit (C) Meter unit (B) LED unit (1) Torque converter oil temperature gauge (16) Speedometer (2) Torque converter oil temperature caution lamp (17) Hydraulic oil temperature caution lamp (3) Engine coolant temperature caution lamp (18) Hydraulic oil temperature gauge (4) Engine coolant temperature gauge (19) Fuel level caution lamp...
Page 74 GENERAL VIEW OPERATION Display of liquid crystal unit (A) Standard screen (D) Warning screen (B) ECO guidance screen (E) User menu screen (C) Maintenance time warning screen (28) Message display (40) Preheating pilot lamp (29) Auto-digging pilot lamp (40) Transmission cut-off pilot lamp (30) Auto-greasing pilot lamp (41) Fan reverse display (31) Directional selector pilot lamp (if equipped)
Page 75: Other Equipment Name
OPERATION GENERAL VIEW *ECSS: Electronically Controlled Suspension System * At sections (36) and (40), 2 types of pilot lamp are prepared. OTHER EQUIPMENT NAME Inside of cab (1) 24 V power supply (8) Cup holder (2) Rearview monitor (9) Open lock for cab L.H. door (3) Ashtray (10) Cab door handle (4) Open knob for alternate exit of cab...
Page 76 GENERAL VIEW OPERATION Outside of cab (1) Slow-blow fuse (3) Articulation lock pin (2) Dust indicator (4) Toolbox...
Page 77 OPERATION GENERAL VIEW (5) KDPF (10) System operating lamp (6) DEF injector (11) DEF pump (7) SCR assembly (12) DEF filter (8) Komatsu Closed Crankcase Ventilation (hereafter (13) DEF tank KCCV) ventilator (9) Battery disconnect switch...
Page 78: Explanation Of Components
EXPLANATION OF COMPONENTS OPERATION EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT FF: Failure display screen (A) Warning display...
Page 79 NOTICE If the lamps, alarm buzzer, etc. do not work, the machine monitor may be failed or the electric wiring may have breakage. In this case, ask your Komatsu distributor for repair. REMARK When the engine is started, the battery voltage may suddenly drop depending on the temperature and the bat- tery condition.
Page 80 5 seconds, and then screen goes out. End screen with message If there is any message from your Komatsu distributor, it is displayed on end screen DD for 5 seconds, and then the screen goes out. In this case, turn the starting switch to ON position to re-check the message, and if it is the message requesting response, send back your reply.
Page 81 OPERATION EXPLANATION OF COMPONENTS For the method of displaying and replying the messages, see “MESSAGE DISPLAY (3-87)”. End screen with Operational Advice If there is any Operational Advice, Operational Advice is displayed on end screen EE for 5 seconds, and then the screen goes out.
Page 82 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE If any trouble occurs during operation, the standard screen BB changes to the failure display screen FF. When ENTER switch is pressed while guidance icon (1) is dis- played, the “Current Abnormality”...
Page 83 OPERATION EXPLANATION OF COMPONENTS (1) Torque converter oil temperature caution lamp (7) Seat belt caution lamp (2) Engine coolant temperature caution lamp (8) Action level (3) Warning display (A) (9) Brake oil pressure caution lamp (4) Warning display (B) (10) Hydraulic oil temperature caution lamp (5) Centralized warning lamp (11) Fuel level caution lamp (6) Guidance icon...
Page 84 Stop the operation and move the machine to a safe Sounds in- Lights up Lights up place, then ask your Komatsu distributor for inspec- termittently in red tion and maintenance. High If there is an overrun related display, reduce the en- gine speed and machine travel speed while continu- ↑...
Page 85 (A) Caution lamp (B) Action level (C) Failure code Code to indicate the content of the failure. Notify it when calling your Komatsu distributor. (D) Failure name (E) Message Take appropriate remedies according to the displayed message. (F) Contact telephone number The telephone number of the contact such as your Komatsu distributor is displayed.
Page 86 EXPLANATION OF COMPONENTS OPERATION (G) Guidance icon On the “Current Abnormality” list screen, the following switches displayed in guidance icon (G) can be operated. UP switch: Moves to the previous page. When on the first page, it moves to the last page. DOWN switch: Moves to the next page.
Page 87 At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance. When action level is not displayed and lamp lights up in red If the brake oil pressure is below the specified value while the engine is stopped, the caution lamp lights up in red.
Page 88 The caution lamp lights up in yellow. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for the inspection and maintenance as needed. WORK EQUIPMENT SYSTEM CAUTION LAMP The work equipment system caution lamp warns about abnor- mality in the work equipment system.
Page 89 If the brake oil temperature caution lamp frequently lights up, record the operation, travel speed, and the state of braking just before the lamp lights up, then consult your Komatsu distributor. DEF LEVEL CAUTION LAMP DEF level caution lamp alerts when DEF tank level becomes low.
Page 90 The auto-greasing caution lamp warns about the abnormality related to the auto-greasing. If the caution lamp lights up in red, stop the work immediately and ask your Komatsu distributor for inspection and mainte- nance. GREASE LEVEL OF AUTO-GREASING SYSTEM CAUTION LAMP The grease level of auto-greasing system caution lamp warns about low level of remaining grease in the grease pump.
Page 91 If the caution lamp lights up in yellow and action level “L01” is displayed, always perform inspection and maintenance after the operation is finished. Ask your Komatsu distributor for the inspection and mainte- nance as needed. STEERING OIL PRESSURE CAUTION LAMP The steering oil pressure caution lamp warns the operator that the steering oil pressure is below the specified value.
Page 92 The caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
Page 93 The caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
Page 94 Whenever the caution lamp lights up in yellow, it is necessary to ask your Komatsu distributor to go off this caution lamp. When stopping the engine, stop it after running it at low idle for approximately 5 minutes. For details, see “METHOD FOR STOPPING ENGINE (3-188)”.
Page 95 The caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
Page 96 See “METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT”. If it occurs again in a short time, the coolant may be leaking from the radiator. Ask your Komatsu distributor for inspection and maintenance. CHARGE LEVEL CAUTION LAMP Charge level caution lamp warns about abnormality in the charging system while the engine is running.
Page 97 For operations on the Maintenance menu screen, see “MAINTENANCE SCREEN SETTING (3-74)”. • By default, the maintenance time caution lamp (yellow) is set to light up when the remaining time reaches 30 hours. However, you can change this setting. To change the setting, ask your Komatsu distributor. 3-29...
Page 98 EXPLANATION OF COMPONENTS OPERATION CENTRALIZED WARNING LAMP The centralized warning lamp lights up in red and at the same time the alarm buzzer sounds intermittently when the machine is in any of the following conditions. Machine conditions under which centralized warn- Other monitor displays ing lamp lights up When action level L02, L03, or L04 is displayed on...
Page 99 OPERATION EXPLANATION OF COMPONENTS PILOT DISPLAY AND METER DISPLAY Pilot display (1) Message display (14) Remote positioner display (2) Auto-digging pilot lamp (15) Shift lever position display (3) Auto-greasing pilot lamp (16) Automatic shift pilot lamp (4) Directional selector pilot lamp (if equipped) (17) Torque converter lockup mode display (5) ECSS pilot lamp (18) Shift hold pilot lamp...
Page 100 EXPLANATION OF COMPONENTS OPERATION Meter display (26) Engine tachometer (27) Speedometer (28) R.H. meter (29) L.H. meter (30) Torque converter oil temperature gauge (31) Engine coolant temperature gauge (32) ECO gauge (33) DEF level gauge (34) Hydraulic oil temperature gauge (35) Fuel gauge * At sections (14) and (19), 2 types of pilot lamp are prepared.
Page 101 OPERATION EXPLANATION OF COMPONENTS CLEARANCE LAMP PILOT LAMP The clearance lamp pilot lamp lights up when the clearance lamps are turned on. AUTO-DIGGING PILOT LAMP The auto-digging pilot lamp lights up while the auto-digging function is enabled. AUTO-GREASING PILOT LAMP The auto-greasing pilot lamp lights up while the auto-greasing system is working.
Page 102 EXPLANATION OF COMPONENTS OPERATION ECSS PILOT LAMP The ECSS pilot lamp lights up when ECSS is effective. When ECSS switch is turned ON, the display pops up. For detail, see “ECSS SWITCH (3-98)”. 2-STAGE LOW IDLING PILOT LAMP (if equipped) The 2-stage low idling pilot lamp lights up when the 2-stage low idle is effective.
Page 103 OPERATION EXPLANATION OF COMPONENTS SHIFT HOLD PILOT LAMP The shift hold pilot lamp lights up when the shift hold function works. TORQUE CONVERTER LOCKUP MODE DISPLAY The torque converter lockup pilot lamp displays the set state of the torque converter lockup mode. By selecting torque converter lockup mode selector switch, one of the following lamps lights up.
Page 104 MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. (A): There is unread message (B): There is any read message to which no reply is made. To read the message, see “MESSAGE DISPLAY (3-87)”.
Page 105 Also, keep combustible materials away from the exhaust pipe outlet to prevent a fire. • If there is a thatched roof, dead leaves, paper, or other combustible matter near the machine, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-130)”. Aftertreatment devices regeneration display indicates the re- generation state of the aftertreatment devices.
Page 106 EXPLANATION OF COMPONENTS OPERATION At the same time, action level “L02” is displayed. Move the machine to a safe place, stop the engine, then per- form the inspection and maintenance. The secondary steering self-check function is installed. For detail, see “SELF-CHECK FUNCTION FOR SEC- ONDARY STEERING (3-199)”.
Page 107 OPERATION EXPLANATION OF COMPONENTS ECO GUIDANCE ECO guidance is displayed during the operation that lowers the fuel efficiency, and support energy saving oper- ation for reducing the fuel consumption. The details of the guidance are as follows. REMARK Display/Non-display of ECO guidance can be switched. For the method of switching the display, see “SWITCH DISPLAY/NON-DISPLAY OF ECO GUIDANCE (3-59)”.
Page 108 EXPLANATION OF COMPONENTS OPERATION GUIDANCE OF ACCELERATOR PEDAL DEPRESSING LIMIT If the accelerator pedal is depressed too much when the travel direction is changed, the notification of accelerator pedal de- pressing limit is displayed on the monitor. In order to reduce fuel consumption during directional selec- tion, try not to operate the accelerator pedal excessively.
Page 109 OPERATION EXPLANATION OF COMPONENTS DEF LOW LEVEL GUIDANCE At 15 seconds after the starting switch is turned to ON position and the standard screen is displayed, if the oper- able time estimated from current DEF level and the latest average DEF consumption is shorter than 8 hours, DEF Level Low Error guidance is displayed.
Page 110 EXPLANATION OF COMPONENTS OPERATION ENGINE TACHOMETER The engine tachometer indicates the engine speed. If the engine speed is higher than the allowable range during operation, the engine overrun caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently.
Page 111 OPERATION EXPLANATION OF COMPONENTS FUEL GAUGE Fuel gauge shows the amount of fuel in the fuel tank. If the indicator is in the red range, the fuel level caution lamp lights up in red. The fuel level is below 42 ℓ. Check the fuel lev- el, and add fuel.
Page 112 EXPLANATION OF COMPONENTS OPERATION Service meter display Indicates the integrated operating hours of the machine. When the engine has run, the service meter advances even if the machine is not being operated. The service meter advances by 0.1 for 6 engine running mi- nutes and by 1 for 1 engine running hour, regardless of the en- gine speed.
Page 113 OPERATION EXPLANATION OF COMPONENTS Fuel consumption gauge display Indicates the average fuel consumption of the machine. (C): Average fuel consumption in a day (D): Split fuel consumption (under measuring) (E): Split fuel consumption (when measuring is stopped) REMARK Display on the fuel consumption gauge can be switched be- tween the average fuel consumption per day (from 0:00 am of the day to 0:00 am of the next day) and the average fuel con- sumption during an selected period (split fuel consumption).
Page 114 EXPLANATION OF COMPONENTS OPERATION The function of each switch varies depending on the screen of the machine monitor. (1) UP switch (5) RETURN switch (2) Air conditioner switches, numeric keypad (6) DOWN switch (3) Menu switch (7) Guidance icon (4) ENTER switch MENU SWITCH When this switch is pressed on the standard screen, the follow- ing user menu screen is displayed.
Page 115 OPERATION EXPLANATION OF COMPONENTS RETURN SWITCH Pressing RETURN switch cancels a selection or changes, and returns the screen to the previous screen or the standard screen. UP SWITCH Pressing UP switch moves the cursor up by one item. When on the first line, it moves to the last line.
Page 116 EXPLANATION OF COMPONENTS OPERATION REMARK The switches effective on each screen can be checked with the guidance icon. This function is not available when you press a switch not marked by the guidance icon or you press the guidance icon it- self.
Page 117 OPERATION EXPLANATION OF COMPONENTS The user menu consists of the following kinds. The menu screen can be changed by pressing the menu switch (1). (A): “Energy Saving Guidance” (B): “Machine Setting and Information” (C): “Aftertreatment Devices Regeneration” (D): “SCR Information” (E): “Maintenance”...
Page 118 EXPLANATION OF COMPONENTS OPERATION (D) “SCR Information” • Check of DEF level • Information on DEF system (E) “Maintenance” • Check and reset of various maintenance remaining times (F) “Monitor Setting” • “Rearview Monitor Setting” • “Meter Display Selection” • “Screen Adjustment”...
Page 119 OPERATION EXPLANATION OF COMPONENTS (4) RETURN switch Cancels a selection or changes, and returns to the previous screen or the standard screen. REMARK • If no switch is operated for 30 seconds on the user menu screen, the screen automatically returns to the previous screen or the standard screen.
Page 120 EXPLANATION OF COMPONENTS OPERATION REMARK For the definition and display change method of “1 Day” and “Split Time”, see “SET DISPLAY OF FUEL CON- SUMPTION GAUGE (3-56)”. When “Average Fuel Consumption Display” is set to “1 Day” “1 Day” is displayed on the place shown with arrow in the fig- ure.
Page 121 OPERATION EXPLANATION OF COMPONENTS ECO GUIDANCE RECORD On “ECO Guidance Records” screen, the frequency of display of the ECO guidance on a daily basis or during the split meas- urement period and “Operational Advice” are displayed. Select ECO Guidance Records from Energy Saving Guidance menu screen, then press ENTER switch (1).
Page 122 EXPLANATION OF COMPONENTS OPERATION When display of “Average Fuel Consumption Display” is set to “Split Time”, and split time measurement is stopped (C) Display while measurement is stopped (D) Dates and times when the measurement is started and stopped To start the split time measurement, see the guidance icon and press ENTER switch (1).
Page 123 OPERATION EXPLANATION OF COMPONENTS • When display of the “Last 12 hours” is selected • When display of the “Last 7 days” is selected REMARK The graph of the “Last 12 hours” is updated every hour of the service meter reading. The graph of the “Last 7 days”...
Page 124 EXPLANATION OF COMPONENTS OPERATION DISPLAY SETTING On the “Configurations” menu, it is possible to perform follow- ing settings. • Setting “Average Fuel Consumption Display” • Switching ON/OFF of “ECO Gauge Display” • Setting “ECO Gauge Display Fuel Target Value” • Switching ON/OFF of ECO guidance •...
Page 125 OPERATION EXPLANATION OF COMPONENTS Select “1 Day” or “Split Time”, then press ENTER switch (1). The default is “1 Day”. To cancel, press RETURN switch (2). “1 Day” Displays the average fuel consumption in 1 day from 0:00 a.m. of the day to 0:00 a.m. of the next day. Reset at 0.00 a.m.
Page 126 EXPLANATION OF COMPONENTS OPERATION Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the ECO gauge. “OFF” Does not display the ECO gauge. To cancel, press RETURN switch (2). The default is “ON”. REMARK For the ECO gauge, see “ECO GAUGE (3-43)”. If the “ECO Gauge Display”...
Page 127 OPERATION EXPLANATION OF COMPONENTS Using UP switch (2) or DOWN switch (3) to set the value, and press ENTER switch (1). (2) UP switch Increases the target fuel consumption value by 1 ℓ/h. (3) DOWN switch Decreases the target fuel consumption value by 1 ℓ/h. To cancel, press RETURN switch (4).
Page 128 EXPLANATION OF COMPONENTS OPERATION Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the ECO guidance. “OFF” Does not display the ECO guidance. To cancel, press RETURN switch (2). The default is “ON”. REMARK • For the ECO guidance, see “ECO GUIDANCE (3-39)”. •...
Page 129 OPERATION EXPLANATION OF COMPONENTS Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the operational advice on the end screen. “OFF” Does not display the operational advice on the end screen. To cancel, press RETURN switch (2). The default is “ON”. REMARK In the “Operational Advice”...
Page 130 EXPLANATION OF COMPONENTS OPERATION Select “E light Mode / E Mode Selection” on “Machine Set- ting and Information” menu, and press ENTER switch (1). Select the mode, then press ENTER switch (1). • “E light Mode” • “E Mode” The default is “E light Mode”. RADIATOR FAN MANUAL REVERSE MODE CAUTION When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth, etc.
Page 131 OPERATION EXPLANATION OF COMPONENTS Select “Manual Fan Reverse Mode” on the “Machine Set- ting and Information”, and press ENTER switch. REMARK The fan rotation switches from the normal direction to the reverse direction only when all of the following conditions are met.
Page 132 EXPLANATION OF COMPONENTS OPERATION If the condition for reversing the fan is not satisfied, changeover condition waiting pilot lamp (4) lights up in red. Set the engine speed to high idle and perform cleaning. After finishing cleaning, set the engine speed to low idle. If the menu switch is pressed on the standard screen, the screen shown in the figure is displayed.
Page 133 Initially, “Mode A” is selected. When you want other than above settings for the duration and cycle of the fan reverse rotation, consult your Komatsu distributor. REMARK The fan rotation switches from the normal direction to the reverse direction only when all of the following conditions are met.
Page 134 EXPLANATION OF COMPONENTS OPERATION When the set changeover time elapses, fan reverse pilot lamp (2) flashes and lights up. If the condition for reversing the fan is not satisfied, changeover condition waiting pilot lamp (3) lights up in red. The fan returns from the reverse rotation to the normal when the set duration for the reverse rotation elapses.
Page 135 OPERATION EXPLANATION OF COMPONENTS On “Machine Setting and Information” menu, select “2- Stage Low Idle Setting” and press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” The 2-stage low idling operates, and the low idle speed in- creases.
Page 136 EXPLANATION OF COMPONENTS OPERATION Select “Bucket Level Position Selection” on “Machine Set- ting and Information” menu, then press ENTER switch (1). “Bucket Level Position Selection” allows the settings for 3 types of bucket A to C. “Bucket Level Position Adjustment” When using a newly delivered machine or installing another bucket to a currently used machine, you must adjust the level position of the bucket.
Page 137 OPERATION EXPLANATION OF COMPONENTS According to the screen instructions, set the bucket hori- zontal, lower the boom to the ground and press ENTER switch. The screen switches to STEP2. According to the screen instructions, raise the boom to the highest position. When this operation ends successfully, the bucket level position is adjusted as intended.
Page 138 EXPLANATION OF COMPONENTS OPERATION AUTO KICK DOWN SETTING When the shift mode is set to the digging mode automatically, auto-kickdown shifts the gear speed to 1st automatically and eliminates operator's operation. Select “Auto Kick Down Setting” on “Machine Setting and Information”...
Page 139 OPERATION EXPLANATION OF COMPONENTS Press ENTER switch (1) to reset or press RETURN switch (2) to cancel resetting. AUTO IDLE STOP TIMER SETTING Stops the engine automatically when the idle state continued for a predetermined time. The auto idle stop works only when all of the following conditions are met. •...
Page 140 EXPLANATION OF COMPONENTS OPERATION Select the operating time of the auto idle stop, and press ENTER switch (1). REMARK Selecting “OFF” disables operation of the auto idle stop. If the idle state is continued up to 30 seconds before the current auto idle stop timer setting , the countdown screen is displayed on the standard screen.
Page 141 For details of the aftertreatment devices regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-130)”. The operation methods and the contents of the display of KDPF regeneration and urea SCR regeneration are common.
Page 142 EXPLANATION OF COMPONENTS OPERATION SCR INFORMATION Each item in “SCR Information” menu (D) is for displaying infor- mation related to SCR and DEF. For details of “SCR Information”, see “HANDLE UREA SCR SYSTEM WARNING (3-139)”. MAINTENANCE SCREEN SETTING Each item on “Maintenance” menu screen (E) is used for dis- playing and setting the notification relevant to maintenance.
Page 143 The replacement intervals in “Air Cleaner Cleaning or Change” and “Coolant” are not set initially. If you want to change the setting for the maintenance interval and the maintenance notice time, consult your Komatsu distrib- utor. When the maintenance time caution lamp (2) is lit on the stand- ard screen, press the menu switch, and the screen automati- cally displays the “Maintenance”...
Page 144 Input the password for restriction of use by using the nu- meric keypad, then press ENTER switch (1). REMARK For the setting, changing, or canceling the password, ask your Komatsu distributor. The screen changes to Maintenance Due Time Reset screen. When ENTER switch (1) is pressed, the following reconfir- mation screen is displayed.
Page 145 OPERATION EXPLANATION OF COMPONENTS Select “Rearview Monitor Setting” on the “Monitor Setting” menu screen, and press ENTER switch (1). Reference line display The is used to change ON/OFF of the reference line on the rearview monitor. Select “Guide Line Display Mode” from the “Rearview Monitor Setting”...
Page 146 EXPLANATION OF COMPONENTS OPERATION Select “Reverse-interlock Selection mode” on the “Rear- view Monitor Setting” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays images on the rear view monitor only when trav- eling in reverse.
Page 147 OPERATION EXPLANATION OF COMPONENTS Select “Meter Display Selection” on the “Monitor Setting” menu screen, then press ENTER switch (1). SELECT L.H. METER DISPLAY This is used for the selection of the items to be displayed on the L.H. meter display. Select “LH Meter Display Selection”...
Page 148 EXPLANATION OF COMPONENTS OPERATION REMARK For details of each item, see “L.H. AND R.H. METER (3-43)”. The default of L.H. meter is “SMR: Service Meter”. SELECT R.H. METER DISPLAY This is used for the selection of the items to be indicated on the R.H. meter display. Select “RH Meter Display Selection”...
Page 149 OPERATION EXPLANATION OF COMPONENTS Adjust the brightness by using the switch panel. The brightness can be adjusted individually in the day and night modes. (1) Menu switch Brightness is set to default. (2) UP switch Brightness increases. (Moves the indicator to the right by one division.) (3) DOWN switch Brightness decreases.
Page 150 EXPLANATION OF COMPONENTS OPERATION Select “GPS Synchronization” from the “Clock Adjustment” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” Sets the date and time automatically. “OFF” Does not set the date and time automatically. (Can be set manually.) REMARK This setting is held even if the starting switch is turned to OFF...
Page 151 OPERATION EXPLANATION OF COMPONENTS Select “Calendar” from the “Clock Adjustment” menu, then press ENTER switch (4). REMARK As long as “ON” is selected for the “GPS Synchronization”, “Calendar” is not selectable. The “Calendar” screen is displayed. When year display (A) is highlighted in yellow, operate the switches as follows to change year display.
Page 152 EXPLANATION OF COMPONENTS OPERATION When day display (C) is highlighted in yellow, operate the switches as follows to change day display. When it is not necessary to change the day setting, press ENTER switch (4). (1) UP switch Advances calendar one day. (2) DOWN switch Puts calendar back one day.
Page 153 OPERATION EXPLANATION OF COMPONENTS When minute display (E) is highlighted in yellow, operate the switches as follows to change minute display. When it is not necessary to change the minute setting, press ENTER switch (4). (1) UP switch Advances time one minute. (2) DOWN switch Puts time back one minute.
Page 154 EXPLANATION OF COMPONENTS OPERATION Select “Daylight Saving Time” from the “Clock Adjustment” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the time 1 hour forward. “OFF” Returns the time to the original. REMARK Daylight saving time or summer time means moving the clock forward an hour to take advantage of the fact that the sun rises...
Page 155 This setting is held even if the starting switch is turned to OFF position. MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this User Message menu (G). When there is any message, message display (1) of the stand- ard screen lights up.
Page 156 EXPLANATION OF COMPONENTS OPERATION (A): There is unread message. (B): There is any read message to which no reply is made. Reply to the message in accordance with the replying method mentioned later. REMARK • While message display (1) is lit on the standard screen, when menu switch (2) is pressed, User Message menu screen (G) is displayed automatically.
Page 157 OPERATION EXPLANATION OF COMPONENTS After inputting a selected item number, press ENTER switch (2). “Do you send Numeric Input?” When this message is dis- played, press ENTER switch (2) again. The input value will be sent out. To cancel, press RETURN switch (1). The input number is cleared.
Page 158 NOTICE If the monitor screen is displayed during other operations while the starting switch is at OFF position, there is proba- bly a failure in the equipment, so ask your Komatsu dis- tributor for inspection. 3-90...
Page 159: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES (1) ECSS switch (2) Front working lamp switch 3-91...
Page 160 EXPLANATION OF COMPONENTS OPERATION (3) Engine shutdown secondary switch (18) Beacon lamp switch (if equipped) (4) Gear speed switch (19) Auto-greasing switch (5) Hazard lamp switch (20) Rear working lamp switch (6) Horn switch (21) Rear heated wire glass switch (7) Lamp switch (22) Room lamp switch (7) Turn signal lever...
Page 161 OPERATION EXPLANATION OF COMPONENTS CIGARETTE LIGHTER The cigarette lighter is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its origi- nal position after a few seconds, so pull it out to use it. If the cigarette lighter is removed, the socket can be used as an 85 W (24 V x 3.5 A) power supply.
Page 162 EXPLANATION OF COMPONENTS OPERATION HORN SWITCH If you press the horn switch, the horn sounds. KICKDOWN SWITCH The kickdown switch is located at the top of the boom control lever. In the manual shift mode, each time the kickdown switch is pressed while the machine is traveling in FORWARD 2nd (F2) or higher gear speed, the transmission is downshifted by one gear speed.
Page 163 OPERATION EXPLANATION OF COMPONENTS REMARK • To cancel the kickdown, operate the directional lever. In the manual shift mode, the kickdown can also be canceled by setting the gear speed switch to a position other than 2nd. • When the starting switch is turned to OFF position and then to ON position again while the gear speed is kicked down, the kickdown is canceled.
Page 164 If the parking brake was used as a secondary brake when the machine was traveling at high speed, ask your Komatsu distributor for inspection of the parking brake system. The parking brake switch is used to apply the parking brake.
Page 165 OPERATION EXPLANATION OF COMPONENTS HOLD SWITCH When HOLD switch on the side face of the boom control lever knob is pressed to fix the gear speed in the auto-shift mode, the transmission is fixed to the gear speed indicated on shift in- dicator (A) of the machine monitor and shift hold pilot lamp (B) lights up.
Page 166 EXPLANATION OF COMPONENTS OPERATION The room lamp switch illuminates the room lamp. Position (A): OFF (goes out) Position (B): Lights up when cab door opens. Position (C): ON (lights up) REMARK • The room lamp lights up even when the starting switch is at OFF position.
Page 167 OPERATION EXPLANATION OF COMPONENTS NOTICE • Before operating the ECSS switch, be sure to stop the machine and lower the work equipment to the ground. • When performing inspection or maintenance, lower the work equipment to the ground first, press ECSS switch to OFF position, then start the work.
Page 168 EXPLANATION OF COMPONENTS OPERATION Use the hazard lamp switch when you need to park the ma- chine on a road due to machine failure or during emergency only. Position (A): The turn signal lamps and the turn signal pilot lamp flash. Position (B):The lamps go out.
Page 169 Even if the engine was stopped while P mode had been set, the mode becomes E light mode/E mode when the engine is started next. If you want to make any change to the setting at the engine start, consult your Komatsu distributor. 3-101...
Page 170 EXPLANATION OF COMPONENTS OPERATION TRANSMISSION SHIFT MODE SELECTOR SWITCH The transmission shift mode selector switch is used to switch the transmission between the automatic shift and manual, and also change the shift point when the auto-shift mode is select- When this switch is at (B) or (C) position, the transmission is set in the auto-shift mode and the automatic shift pilot lamp lights up on the machine monitor.
Page 171 OPERATION EXPLANATION OF COMPONENTS The directional selector enable switch on R.H. switch panel is used to enable the directional selector switch. The basic operation is as follows. Position (A): Directional selector switch is enabled. Position (B): Directional selector switch is disabled. When setting the directional selector enable switch on R.H.
Page 172 EXPLANATION OF COMPONENTS OPERATION SECONDARY STEERING SWITCH The secondary steering switch is used to operate the secon- dary steering manually. Even when the engine is stopped, pressing this switch allows operating the steering. Position (A): ON The pilot lamp in the switch and the secondary steering pilot lamp on the machine monitor light up, and you can operate the steering.
Page 173 OPERATION EXPLANATION OF COMPONENTS The work equipment lock switch (1) is a device used to lock the operation of the work equipment. Keep pulling the lock (2) of switch in the direction (b) shown by arrow and push it into the direction (c). The switch automatically returns to its original position when re- leasing your hand from the switch.
Page 174 OFF position but the engine does not stop. • Use the engine shutdown secondary switch only in an emergency. Contact your Komatsu distributor for repair immediately when there is any abnormality on this switch. • If the engine shutdown secondary switch is set to STOP ENGINE position by mistake while the ma- chine is operating normally, “Engine Shutdown Secondary SW in Operation”...
Page 175: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS Raise cover (1) and open it. There is a switch under the cover. Pull up the switch, and the engine stops. (a) STOP ENGINE: When abnormal (switch is set up) (b) NORMAL: When normal (switch is set down) •...
Page 176 0 to 129 mm 0 to 162 mm NOTICE Do not operate the steering tilt lock lever repeatedly with an excessive force. The lever can be loosened or its angle can be displaced. In such case, ask your Komatsu distributor for inspection. 3-108...
Page 177 OPERATION EXPLANATION OF COMPONENTS BRAKE PEDAL WARNING • While traveling downhill, use the engine brake with the transmission cut-off function being shut off. The brake pedals installed on right and left sides of the steering post provide the same function. •...
Page 178 EXPLANATION OF COMPONENTS OPERATION ACCELERATOR PEDAL The accelerator pedal is used to adjust the speed and output of the engine. It freely controls the engine from low idle to high idle. BUCKET CONTROL LEVER NOTICE Even if the engine is stopped, if the starting switch is at ON position and lock of the work equipment is cancelled (pilot lamp is not lit), the work equipment can be operated.
Page 179: Other Equipment
OPERATION EXPLANATION OF COMPONENTS BOOM CONTROL LEVER The boom control lever is used to control the boom. NOTICE Do not use “FLOAT” position when lowering the bucket. Use “FLOAT” when “LEVELING WORK (3-209)”. Position (a): RAISE If the boom control lever is pulled further from “RAISE” position, the lever stops in that position.
Page 180 EXPLANATION OF COMPONENTS OPERATION CAB DOOR HANDLE While the key is not in the lock position, pull right side (1) of the door handle with the right hand, and push left side (2) with the thumb, and the door opens to the full open position, OPEN HANDLE FOR CAB L.H.
Page 181 OPERATION EXPLANATION OF COMPONENTS UNLOCK KNOB FOR SLIDE WINDOW OF CAB Use this to open and close the door window glass up and down. Grip unlock knob (1) to release the lock, then move it to the lower LOCK position and release it. There are 3 stages for LOCK position (A).
Page 182 EXPLANATION OF COMPONENTS OPERATION Pull up door knob (1). Hold door knob (1) and pull it toward the rear of the ma- chine. Remove the guide rail of the door knob from guide pin (2) fixed to the cab and unlock the right side door. Open the right side door wide and go out.
Page 183 OPERATION EXPLANATION OF COMPONENTS NOTICE If the door is closed without holding door knob (1), the plastic part of the door knob hits against guide pin (2) on the cab side and may be broken. Always close the door while holding door knob (1). COOL BOX Drink, hand towel, etc.
Page 184 EXPLANATION OF COMPONENTS OPERATION NOTICE While removing the ashtray, if it is stuck in the console cover and hard to be removed, open lid (A) of ashtray, then hold the ashtray body (B) and twist it to remove. If you hold lid (A) of ashtray and twist it, the ashtray may break.
Page 185 OPERATION EXPLANATION OF COMPONENTS Inside rear console box Loosen knobs (1) (2 places), then remove cover (2). Fuse box- es are A, B, and C inside. Fuse capacities and circuit names Fuse box A Fuse Name of circuit capacity 20 A Starting switch 10 A Hazard lamp...
Page 186 EXPLANATION OF COMPONENTS OPERATION Fuse box B Fuse Name of circuit capacity 15 A Horn 20 A Transmission control 5 A Parking brake 5 A Secondary steering 15 A Work equipment positioner 10 A Backup lamp and brake lamp 30 A Wiper and washer 20 A Air conditioner blower 5 A Main compressor (10)
Page 187 OPERATION EXPLANATION OF COMPONENTS FRAME LOCK BAR WARNING • When performing maintenance or transporting the machine, always set the frame lock bar to LOCK position. • Always disengage the frame lock bar when traveling. If it is not disengaged, the steering wheel be- comes inoperative and this may lead to serious personal injury or death.
Page 188 EXPLANATION OF COMPONENTS OPERATION Turn the handle (2) clockwise from C to D. You can keep the towing pin in the pulled up position. Pass the towing pin through the ring of wire rope while pushing in the towing pin in the reverse order of steps 1 to Fold the handle (2) toward the rear side of the machine.
Page 189 OPERATION EXPLANATION OF COMPONENTS Pull lever (2) of rear full-length fender (1) toward you to un- lock. Lower lock pin (3) to unlock. Hold handle (4) and slide rear full-length fender (1) out- ward. Raise lock lever (5) and turn it, then lower the lock lever at LOCK position (L).
Page 190 EXPLANATION OF COMPONENTS OPERATION Pull down engine side cover (1). Raise lock lever (2) and turn it, then lower the lock lever at FREE position (F). Rear full-length fender (3) is unlocked. Hold handle (4) of rear full-length fender (3) and slide it in- ward, and return the rear full-length (3) fender to its origi- nal position.
Page 191 OPERATION EXPLANATION OF COMPONENTS This is installed to the right inside of the operator's cab. The directions are described on the nameplate affixed to the fire extinguisher. Carefully read and understand them before- hand for emergencies. BATTERY DISCONNECT SWITCH CAUTION •...
Page 192 EXPLANATION OF COMPONENTS OPERATION The battery disconnect switch is used to cut out the electricity from the battery. Open the cover on the right side of the machine, and open bat- tery disconnect cover (1). Raise rubber cover (2), and the switch is seen. (O): OFF position It allows moving in and out of switch key (3) and used for cut- ting off the current from the battery.
Page 193 • After the starting switch has been turned off, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. • While DEF system devices are operating, the system operating lamp lights up to return DEF to the tank.
Page 194 EXPLANATION OF COMPONENTS OPERATION Lubrication time: 12 minutes When changing the settings of the lubrication cycle for the heavy-duty operations, consult your Komatsu distrib- utor. Method for operating the auto-greasing system The pump with grease tank is located at the position as shown in the figure.
Page 195 OPERATION EXPLANATION OF COMPONENTS Push button switch (1) Turn on display Display values and parameters Set values and parameters (2) Change between setting and display mode Confirm values (3) Actuation of manual lubrication Clear fault message Three-digit LED display During normal operation, the display is off. It is activated by briefly operating one of the two push buttons.
Page 196 The display mode will start with one of two buttons (C). When grease has leaked from pressurized safety valve (1), consult your Komatsu distributor. The pump has an automatic level control. If the grease level falls below “MIN” mark, the lubrication process is stopped with the fault message “FLL”...
Page 197 The control unit is in the FAULT pump running time. mode. The sequence of opera- tions is stopped. If the fault message will appear again after the reset, consult your Komatsu distributor. HANDLE REAR VIEW MONITOR WARNING • Never operate any of the switches while traveling. If you do so, there is a danger that you may make an error in the machine operation, or neglect to watch the travel path ahead for safety, and as a re- sult cause a serious personal injury.
Page 198 EXPLANATION OF COMPONENTS OPERATION HANDLE Komatsu Diesel Particulate Filter (KDPF) CAUTION • Exhaust gas temperature may increase during the aftertreatment devices regeneration and the high temperature may last after the completion of regeneration. Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt.
Page 199 “L04” lights up in red, the engine output is limited to protect the engine and KDPF system. Stop the machine immediately and ask your Komatsu distributor. REMARK • Soot accumulation level (3) can be checked with the “Af- tertreatment Devices Regeneration”...
Page 200 Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may cause failure.
Page 201 OPERATION EXPLANATION OF COMPONENTS When the degree of emergency is high • KDPF soot accumulation caution lamp (2) lights up in red and the action level “L03” lights up in red (4). • If the machine is stopped completely, the screen changes to the “Aftertreatment Devices Regeneration”...
Page 202 EXPLANATION OF COMPONENTS OPERATION Set the parking brake switch to ON position (A) and apply the parking brake. Press the menu switch to display “Aftertreatment Devices Regeneration” screen. Select the manual stationary regeneration, check again safety of the surrounding area and make sure the area is free from irrelevant people or combustible material, then press ENTER switch.
Page 203 OPERATION EXPLANATION OF COMPONENTS REMARK • The explanation of the manual stationary regeneration is displayed in 3 parts on the monitor panel. When ENTER switch is pressed, the regeneration can be started immediately, regardless of which part is dis- played. When RETURN switch is pressed, the display returns to the standard screen.
Page 204 EXPLANATION OF COMPONENTS OPERATION REMARK • The progress of the manual stationary regeneration performed when soot is accumulated can be checked by the number of lighting lamps of soot accumulation level (2). The manual stationary regeneration starts at soot accumulation level “4” or higher and finishes when all the level lamps go out.
Page 205 OPERATION EXPLANATION OF COMPONENTS Operate the menu switch to select “Aftertreatment Devices Regeneration” menu (C) and display “Aftertreatment Devi- ces Regeneration” screen. Select Regeneration Disable and press ENTER switch. The regeneration function is disabled and the regeneration is not performed. REMARK •...
Page 206 The regeneration disable setting is also canceled by turn- ing the starting switch to OFF position to stop the engine. KOMATSU CLOSED CRANKCASE VENTILATION (KCCV) KCCV is a device to clean the gas discharged from the engine crankcase and return it to the engine air intake system.
Page 207 Urea SCR systems by utiliz- ing visible and audible alerts , and engine power derate in addition. Alerts in Inducement of the Komatsu Urea SCR System progresses step by step starting from visual indications on the machine monitor and audible sounds to engine power derate to avoid getting into unsafe conditions.
Page 208 In addition, it may cause failures in the engine system. If DEF out of the standard is filled or used by mistake, contact your Komatsu distributor. About the operation of Urea SCR system The Urea SCR System automatically starts operating as soon as the engine is started.
Page 209 OPERATION EXPLANATION OF COMPONENTS Perform the following procedure. Press the menu switch on the standard screen to display the “SCR Information” screen of the user menu. After a lapse of 3 seconds to stop the machine, “SCR Informa- tion” screen is displayed. “SCR Information”...
Page 210 EXPLANATION OF COMPONENTS OPERATION Inducement status (4): “2 Without treatment, engine power will be derated.” Add DEF to the DEF tank immediately. • Low level Inducement: The audible alert sounds in “Intermittent alarm”. 1 gradation of the DEF level gauge light up in red. The DEF level caution lamp (1) lights up in red.
Page 211 “L04 (Severe Inducement)” is displayed. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 212 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen message (4): “1 Please inspect and maintain SCR system.” Move the machine to the safe place and contact your Ko- matsu Distributor. If operation continues for 5 hour after “Warning” started without taking any actions instructed by the Action Level table, Inducement advances to “Continuous Warning”.
Page 213 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Low level Inducement”.
Page 214 EXPLANATION OF COMPONENTS OPERATION Perform the following procedure. Press the menu switch on the standard screen to display the “SCR Information” screen of the user menu. After a lapse of 3 seconds to stop the machine, “SCR Informa- tion” screen is displayed. “SCR Information”...
Page 215 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen message (5): “2 Without treat- ment, engine power will be derated.” Move the machine to the safe place and contact your Ko- matsu Distributor. The duration time of “Continuous Warning” is 5 hour. The remaining time (Minutes) till the next Inducement status of “Low level Inducement”...
Page 216 Komatsu distributor. Inducement strategy when abnormality is found in the EGR Valve System by the...
Page 217 OPERATION EXPLANATION OF COMPONENTS • Warning: The audible alert sounds in “Intermittent alarm”. The Engine system caution lamp (1) lights up in red. The action level “L03” lights up in red at action level dis- play (3). Press the menu switch to display the “SCR Information” screen.
Page 218 “Temporary Restoration from Inducement” in this manual. If Inducement advances to “Severe In- ducement” and it becomes necessary to restore engine power, use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor. Temporary Restoration from Inducement Temporary Restoration from Inducement is the one of the Inducement strategies allowed to be included in Urea SCR systems.
Page 219 OPERATION EXPLANATION OF COMPONENTS Press the menu switch (1) to display the “SCR Information” screen when the Standard screen is on, only when the Urea SCR system is in “Severe Inducement”. Press the enter switch (2) to display the menu windows popping up in the bottom half of the “SCR Information”.
Page 220 EXPLANATION OF COMPONENTS OPERATION Press the enter switch (2) while the “Engine power Recov- ery” window is displayed. Temporary Restoration from Inducement is activated and engine power deration is relieved to the deration of “Low level Inducement” for the maximum of 30 minutes. The remaining time (minutes/seconds) of “Temporary Re- storation from Inducement”...
Page 221 “METHOD FOR REPLACING DEF FILTER (4-66)”. • If the machine is operated without DEF filter attached, or with the filter other than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine. Never operate the machine without DEF filter attached, nor use the filter other than Komatsu genuine parts.
Page 222 In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX com- munication. If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or damages.
Page 223 OPERATION EXPLANATION OF COMPONENTS NOTICE For more information on KOMTRAX and the Radio Equipment Directive (2014/53/EU), please refer to the Komatsu Europe website. https://www.komatsu.eu/Komtrax-Radio-Equipment-Directive 3-155...
Page 224: Machine Operations And Controls
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. If the machine is inclining, make it level before checking.
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS 11. Check transmission case, axle, hydraulic tank, hoses, and joints for oil leakage. Check for oil leakage. If any problem is found, repair the place where the oil is leaking. 12. Check brake line for oil leakage. Check for leakage of oil or damage to the hoses and tubes.
Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION 20. Check the seat belt and mounting hardware. WARNING Even if no problem can be seen on the appearance of the belt, replace it in accordance with the following schedule whichever date comes sooner. 5 years after the date of seat belt manufacture, or ev- ery 3 years after the start of actual usage.
Page 227 If any problem is found, replace the part. 24. Check the rearview monitor. Check the rearview monitor for problem. If it is failed, ask your Komatsu distributor for repair. METHOD FOR CHECKING BEFORE STARTING Always check the items in this section before starting the engine each day.
Page 228 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK If drain plug (2) is hard to run, apply grease to O-ring (5) of plug (2) according to the following procedure. Place a container under drain hose (4) to catch the drained fuel. Loosen plug (2) and drain all the fuel and sediment through drain hose (4).
Page 229 OPERATION MACHINE OPERATIONS AND CONTROLS Check the reservoir tank. Check that the coolant level is between FULL and LOW marks of the reservoir tank. If the coolant level is low, add coolant to FULL level through the coolant filler port of the reservoir tank. After refilling with coolant, tighten the cap securely.
Page 230 • If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause of it and to perform the repair. • Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap with water to clear the vent hole.
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS Perform the following inspection. • Perform inspection to confirm that the fuses have no defect and their capacity is proper. • Perform inspection to confirm that there is no disconnection or trace of short-circuiting in the electric wiring and no damage to the coating.
Page 232 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the alarm buzzer sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and inspection. DEF injector and/or DEF pump may need to be replaced.
Page 233 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the starting switch to ON position (B). Check the DEF level gauge (1) on the machine monitor. After checking, turn the starting switch back to OFF posi- tion (A). Set the frame lock bar to LOCK position (L). Open up the cover (2) at the right side of the machine, and turn the cap of filler port (3) counterclockwise.
Page 234 MACHINE OPERATIONS AND CONTROLS OPERATION Place the removed cap on the holder (4) inside the cover (2). Bring the magnet (5) on the holder (4) into contact with the metal plate (6) on the cap and fix them. NOTICE If the cap is wrongly placed and foreign materials such as mud and sand are stuck to the cap, it may disturb the operation of the DEF system.
Page 235 OPERATION MACHINE OPERATIONS AND CONTROLS Example of wrong placement By sight gauge (7), add DEF through the filler port until float (8) reaches the line F (9). Line (10) in the sight gauge indicates that it is approxi- mately 5 ℓ below the line F, and the line (12) indicates that it is approximately 10 ℓ...
Page 236 If the fluid does not spout out normally, clean the washer nozzle hole with a fine wire such as a safety pin. • If the condition does not become normal, ask your Komatsu distributor to perform inspection and repair. METHOD FOR CHECKING WIPER FUNCTION Operate the wiper in the “Intermittent”, “Low”, and “High”...
Page 237 When the engine preheating is in operation. METHOD FOR CHECKING HORN Operate the horn switch and check that the horn sounds. If there is any abnormality, ask your KOMATSU distributor for testing and repair. METHOD FOR CHECKING DEFROSTER FUNCTION •...
Page 238 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING SEAT UNIT IN FORE-AND-AFT DIRECTION Operate the lever upward, set the seat to the desired position, and then release the lever. Fore-and-aft adjustment: 152.4 mm (12.7 mm x 12 stages) METHOD FOR RECLINING SEAT NOTICE If the backrest is reclined too far, the headrest or seat belt anchor (when the 3-point seat belt (optional) is installed) may contact the rear window glass, so move it to a position where it does not contact the window glass.
Page 239 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE Do not operate the switch continuously for 1 minute or longer. Doing so can damage the air compres- sor. The seat height is adjusted pneumatically and in stepless. Adjust the suspension strength and seat height by pressing the switch.
Page 240 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING HEADREST IN VERTICAL DIRECTION Move the headrest up or down to the desired height. Adjustment amount: 127 mm METHOD FOR ADJUSTING ARMREST ANGLE Turn the knob to adjust the armrest angle. Amount of adjustment: 35 ° (Forward tilt 12 °, backward tilt 23 °) REMARK You can flip up the armrest.
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS • To increase the damping force, direct the knob toward bot- tom side (A) of the seat. • To decrease the damping force, direct the knob toward top (B) of the seat. Adjustment amount 1st stage: at position (c) 2nd stage: at position (d) 3rd stage: at position (e) 4th stage: at position (f)
Page 242 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR REMOVING AND INSTALLING HEADREST METHOD FOR REMOVING HEADREST When the headrest is not necessary, remove it according to the following procedure. Pull up the headrest until it stops. Pull up the headrest strongly, and it will come out. METHOD FOR INSTALLING HEADREST Insert the headrest into the hole at the seat back.
Page 243 Mirrors A, B: 3 ± 0.5 Nm {0.3 ± 0.05 kgm} Mirrors C, D: 15.7 to 18.6 Nm {1.6 to 1.9 kgm} • If the torque cannot be controlled, ask your Komatsu distributor for adjustment. METHOD FOR ADJUSTING REAR VIEW CAMERA METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE WARNING •...
Page 244 MACHINE OPERATIONS AND CONTROLS OPERATION Adjusting rear view camera angle Adjust the angle of the rear view camera so that people within 1 m} away from the machine's rear part (W) and a point (P) on ground are displayed in the monitor at the operator's seat. Adjust it so that the rear end of counterweight (1) is displayed in the area (a) of 5 to 15 mm from the lower end of monitor at the operator's seat.
Page 245 A part of the machine is shown on the monitor screen. After adjusting, tighten bolts (2) (3 places). If the rear view displayed on the monitor is still misaligned after adjusting the camera angle, the camera must be reset. Consult your Komatsu distributor. 3-177...
Page 246 (E) matches to position (C) that is 1.5 m away from the rear end of the machine. When the reference line is abnormal, change its setting to Non- display and contact your Komatsu distributor. METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING •...
Page 247 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR FASTENING SEAT BELT Sit in the seat and depress the brake pedal fully. Under this condition, adjust the seat so that your back is fitted to the backrest. Sit on the seat, pull the belt on right side, then insert tongue (1) into buckle (2) until a click is heard.
Page 248 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING LEVER STAND IN FORE-AND-AFT DIRECTION While pulling lever (3) up with the left hand, hold armrest (1) with the right hand to move forward or backward, and then re- lease lever (3). Adjustment amount: 180 mm METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING...
Page 249: Method For Starting Engine
The pointer of engine tachometer swings once. If the monitor does not light up, there may be a failure or wire breakage. Ask your Komatsu distributor for inspec- tion. Also, after all of the monitors, gauges, and centralized warning lamp light up, perform the self-check to check that the secondary steering function operates normally.
Page 250 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE • Do not accelerate the engine abruptly until it is warmed up. Do not operate the starting motor continuously for more than 20 seconds. • If the engine does not start, wait for 2 minutes or so, and then try to start the engine again.
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS When the engine starts, release the starting switch key (1). The key returns automatically to ON position (B). When the engine is started, white smoke may come out of the exhaust pipe. It is fine water particles which are produced from moisture or water vapor and which seem white, thus it does not indicate an abnormality.
Page 252 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the key in starting switch (1) to ON position (B). When the ambient temperature is low, preheating pilot lamp (2) lights up and automatic preheating is performed. Keep the starting switch key (1) at ON position until pre- heating pilot lamp (2) goes out.
Page 253: Method For Operations And Checks After Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS TURBOCHARGER PROTECTION FUNCTION The turbo protect function protects the turbocharger by keeping the engine speed at approximately 1000 rpm or less immediately after the engine is started. When the turbo protect function and automatic warm-up function operate at the same time, the turbo protect function is given priority.
Page 254 In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 255 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE Do not accelerate the engine abruptly until it is warmed up. Do not run the engine at low idle or high idle continuously for more than 20 minutes. If it is necessary to run the engine at low or high idle, apply a load from time to time or run it at a mid- range speed.
Page 256: Method For Stopping Engine
(2) and torque converter oil temperature gauge (3) indicate the green range. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distribu- tor. REMARK The cooling fan speed varies according to the following conditions, but it is not abnormal.
Page 257: Method For Starting Machine (Travel Forward And Reverse, And Shifting Gear) And Stopping Machine
OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • After the engine is stopped, DEF in DEF injector and pump is automatically purged and returned to the tank to prevent malfunction of the devices caused by freez- ing of DEF or deposition of urea. For this purpose, the devices keep operating for sev- eral minutes after starting switch (1) is turned to OFF position, and this does not indicate abnormality.
Page 258 MACHINE OPERATIONS AND CONTROLS OPERATION Check that bucket control lever (2) and boom control lever (3) are in HOLD position. Unlock the work equipment (turn OFF pilot lamp (4) in the switch). Operate boom control lever (3) to set the work equipment to travel posture as shown in the figure.
Page 259 Position (R): REVERSE Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does not sound, ask your Komatsu dis- tributor for repairs. REMARK Switch (8) also serves to switch the travel direction among FORWARD, NEUTRAL, and REVERSE.
Page 260 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR SHIFTING GEAR WARNING When the machine is traveling at high speed, do not shift gear abruptly. Use the brake to reduce the travel speed before shifting gear. Shift gear as follows. Set gear speed switch (1) to the desired position to shift gear. Position (a): 1st speed Position (b): 2nd speed Position (c): 3rd speed...
Page 261 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • If the gear speed switch is operated slowly or is stopped between gear positions, the centralized warning lamp may light up and the alarm buzzer may sound. This is not a fail- ure in this case. Operate the gear speed switch so that gear shifting is completed in 2 seconds.
Page 262 MACHINE OPERATIONS AND CONTROLS OPERATION Set directional lever (1) to a desired position. Position (F): FORWARD Position (N): NEUTRAL Position (R): REVERSE Check that the backup alarm sounds when the directional lever is set to R. If the backup alarm does not sound, ask your Ko- matsu distributor for repairs.
Page 263 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STOPPING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Keep depressing the brake pedal until the parking brake pilot lamp lights up on the machine monitor even when the parking brake switch is turned ON. NOTICE Never use the parking brake switch to brake the machine when the machine is traveling except in an emergency.
Page 264 MACHINE OPERATIONS AND CONTROLS OPERATION TRANSMISSION CUT-OFF FUNCTION Turn the transmission cut-off switch ON. The transmission cut-off pilot lamp lights up on the monitor and the following transmission cut-off function works. When the brake pedal is depressed, the brakes are actuated and the transmission is returned to NEUTRAL at the adjusted brake pedal depressing position.
Page 265 OPERATION MACHINE OPERATIONS AND CONTROLS Start the engine with starting switch (1), set parking brake switch (2) to ON (operation) position. Press (a) of transmission cut-off switch (3) to set it to ON position. Check that the transmission cut-off pilot lamp is lit. Depress brake pedal (4) to adjust the set position where the transmission is NEUTRAL.
Page 266: Method For Steering Machine
Check that play (a) of steering wheel is 50 to 100 mm, and that operation of steering wheel is normal. If any problem is found, ask your Komatsu distributor for in- spection. 3-198...
Page 267 OPERATION MACHINE OPERATIONS AND CONTROLS HANDLE SECONDARY STEERING SYSTEM CAUTION • Do not activate the secondary steering except in emer- gency or checking the function. • The secondary steering is continuously operable up to 60 seconds. Continuous operation beyond 60 seconds may damage the system.
Page 268 (green) (2) light up simultaneously. If the steering oil pressure caution lamp (red) or the secondary steering pilot lamp (green) does not light up, it is abnormal. Ask your Komatsu distributor for inspection. CAUTION If the machine is steered during self-check, it may move.
Page 269: Method For Operating Work Equipment
OPERATION MACHINE OPERATIONS AND CONTROLS General view (1) Torque converter lockup switch (3) Shift indicator (indicates actual gear speed) (2) Torque converter lockup mode pilot lamp The lockup is activated or cancelled at the following speed. Forward travel speed Reverse travel speed Lockup km/h km/h...
Page 270 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPERATING BOOM The boom control lever is used to control the boom. NOTICE Do not use “FLOAT” position when lowering the bucket. Use “FLOAT” when “LEVELING WORK (3-209)”. Position (a): RAISE If the boom control lever is pulled further from “RAISE” position, the lever stops in that position.
Page 271 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR AUTO-DIGGING If the auto-kickdown and auto-digging are combined to use, the operator can operate the machine more easily. Switch ON and OFF of the auto-kickdown on the monitor. For the method of switching, see “AUTO KICK DOWN SETTING (3-70)”.
Page 272 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK The boom “RAISE” operation and the bucket “TILT” operation can be performed even if the auto-digging is in operation. When performing the digging work while the priority is given to the productivity, you can per- form the “RAISE”...
Page 273: 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 was used as a secondary brake, ask your Komatsu distributor to inspect the park- ing brake system for any trouble.
Page 274: Method For Checking Bucket Angle
• The most suitable tire pressure and travel speed differ according to the tire type and condition of the travel surface. Contact your Komatsu distributor or tire dealer. • The following shows the appropriate tire pressure and travel speed when the machine is equipped with standard tires (26.5R25XHA2) and runs on the paved surface.
Page 275 OPERATION MACHINE OPERATIONS AND CONTROLS DIGGING WORK WARNING • Never perform digging or scooping operation with the machine articulated. There is a danger that the machine may tip over. • If the ECSS switch is turned ON during travel or with the work equipment raised, the machine starts moving instantly.
Page 276 MACHINE OPERATIONS AND CONTROLS OPERATION Blasted rock At the same time as the bucket thrusts into the target ma- terial, raise the boom to prevent the bucket from going in too far. Raising the boom allows the front wheels to exert sufficient traction.
Page 277 OPERATION MACHINE OPERATIONS AND CONTROLS Set the cutting edge somewhat downward from the hori- zontal. While driving the machine forward, tilt the boom control lever somewhat forward to dig bit by bit as earth and sand are peeled off. Keep on driving the machine forward while adjusting the digging depth by using the boom control lever.
Page 278 If this is not done, the tires will be damaged. Consult your Komatsu distributor or tire dealer. The load and carry method for wheel loaders consists of a cy- cle of scooping → hauling → loading (into a hopper, glory hole etc.).
Page 279 OPERATION MACHINE OPERATIONS AND CONTROLS CROSS DRIVE LOADING When performing digging, set the wheel loader at a right angle to the target stock pile. After digging in and scooping up the load, drive the machine straight back in reverse, then bring the dump truck in between the stock pile and the wheel loader.
Page 280: Remote Positioner
MACHINE OPERATIONS AND CONTROLS OPERATION REMOTE POSITIONER This machine has the functions of the remote bucket positioner and the remote boom positioner. METHOD FOR OPERATING REMOTE BUCKET POSITIONER Raise the boom and dump the bucket. Operate the bucket control lever to the tilt detent position and release your hand from the lever.
Page 281 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPERATING REMOTE BOOM POSITIONER METHOD FOR OPERATING RAISE REMOTE BOOM POSITIONER Set the boom to a desired RAISE stop position above the horizontal. Set the boom control lever to HOLD position and press po- sition (a) of switch (1).
Page 282 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR RELEASING RAISE REMOTE BOOM POSITIONER Raise the boom above the horizontal level. Set the boom control lever to HOLD position and hold down position (a) of switch (1) for more than 1 second. A “beep”...
Page 283 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK When setting RAISE detent, if the boom is very close to the position specified by the positioner (approximately within 2 °), the boom control lever does not set to the detent position. METHOD FOR RELEASING LOWER REMOTE BOOM POSITIONER Set the boom between the horizontal level and approxi- mately 30 cm or more above the ground.
Page 284: Method For Parking Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR PARKING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Do not park the machine on a slope. If it is unavoidable to park the machine on a slope, place the machine at a right angle to the slope face, chock the tires, and then lower the bucket to the ground.
Page 285: Method For Checking After Finishing Work
If oil or coolant leakage or any abnormality is detected, repair it. Check DEF tank, pump, injector, hose, and joint for leakage. If any abnormality is found, ask your Komatsu distributor for repair. Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
Page 286: Lock
MACHINE OPERATIONS AND CONTROLS OPERATION LOCK Lock position Always lock the following places. (1) Fuel tank filler cap (2) Engine side cover (2 places) (3) Cab door (4) Rear grille (5) Air conditioner fresh air filter (6) DEF inspection cover (7) Battery disconnect switch cover The starting switch key is commonly used for locks (1) to (7) .
Page 287 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING CAP WITH LOCK Insert the key into the key slot. Turn the key clockwise, align the matching marks (1) of the key groove and the cap, then open the cap. Position (A): OPEN Position (B): CLOSE (LOCK) METHOD FOR LOCKING CAP WITH LOCK Screw in the cap until it becomes tight, then insert the key into the key slot.
Page 288: Handle Tire
(5) Bead (6) Inner liner (7) Cord Contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. TIRE PRESSURE Check the tire inflation pressure before driving, when the tires are cool.
Page 289 When traveling continuously in load-and-carry operation, choose the appropriate tires to match the operating conditions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged. Consult your Komatsu distributor or tire dealer. 3-221...
Page 290: Handle Air Conditioner
To allow the air conditioner to show its full performance, have inspection and maintenance performed peri- odically. When adding refrigerant or performing other maintenance, special tools and instruments are nee- ded, so ask your Komatsu distributor to perform inspection and maintenance. •...
Page 291: Explanation Of Air Conditioner Equipment
OPERATION HANDLE AIR CONDITIONER EXPLANATION OF AIR CONDITIONER EQUIPMENT (1) OFF switch (6) FRESH/RECIRC air selector switch (2) Auto switch (7) Vent selector switch (3) Air conditioner switch (8) Defroster switch (4) Fan switch (9) Display monitor (5) Temperature control switch Air conditioner monitor (A) Air flow bar (E) Vent display...
Page 292 HANDLE AIR CONDITIONER OPERATION • During auto operation, the air flow is automatically adjusted. The set position of the air flow is indicated on the display monitor. Monitor display Air flow Air flow “LOW” Air flow “MEDIUM 1” Air flow “MEDIUM 2” Air flow “MEDIUM 3”...
Page 293 OPERATION HANDLE AIR CONDITIONER VENT SELECTOR SWITCH In the manual operation, use the vent selector switch to select the vents. • There are 4 modes of vents: FACE, FACE/FOOT, FOOT, and FOOT/DEF. (DEF is selected only when the defroster switch is pressed.) •...
Page 294 HANDLE AIR CONDITIONER OPERATION AUTO SWITCH Use auto switch for automatic selection of the air flow and vents according to the set temperature. This switch is also used as the main switch of the air condition- • When AUTO switch is pressed, AUTO on the display moni- tor lights up to indicate that the air conditioner is in the au- tomatic mode.
Page 295 OPERATION HANDLE AIR CONDITIONER DISPLAY MONITOR The display monitor displays the state of air flow (A), operation of air conditioner (B), set temperature (C), FRESH/RECIRC air (D), vents (E), automatic operation (F), and defroster (G). AIR CONDITIONER SWITCH Use the air conditioner switch to start and stop the cooling, heating, or drying function.
Page 296: Method For Operating Air Conditioner
HANDLE AIR CONDITIONER OPERATION DEFROSTER SWITCH The defroster switch is used to set the vents in the defroster mode. • Use this mode to clear the front glass mist, etc. • When the defroster switch is pressed during automatic op- eration, AUTO on the air conditioner monitor goes out and the defroster mark is displayed.
Page 297 OPERATION HANDLE AIR CONDITIONER Press (A) or (B) of the temperature control switch to set to the desired temperature. The air flow and combination of the vents are automatically selected according to the set temperature, and the air con- ditioner is operated automatically to provide the set tem- perature.
Page 298 HANDLE AIR CONDITIONER OPERATION Turn the air conditioner switch ON. At this time, the air conditioner operation mark lights up on the display monitor. Press (A) or (B) of the temperature control switch to adjust the temperature in the cab. REMARK The air temperature is so adjusted that the temperature in the cab becomes the set temperature when the set tem-...
Page 299 OPERATION HANDLE AIR CONDITIONER METHOD FOR OPERATING DEFROSTER Frost adhered to the outside of the window glass can be removed by defroster operation. Press the defroster switch to set the vents in DEF mode. Press FRESH/RECIRC air selector switch and set it to RE- CIRC mode.
Page 300: Transportation
TRANSPORTATION OPERATION TRANSPORTATION TRANSPORTATION PROCEDURE When transporting the machine, choose the transportation method in reference to the weight and dimensions shown in “SPECIFICATIONS (5-2)”. Note that the “SPECIFICATIONS” (weight and dimensions) vary depending on the type of tire and bucket. LOADING AND UNLOADING WITH TRAILER WARNING •...
Page 301 OPERATION TRANSPORTATION Check that the work equipment control lever is in HOLD position. Lock the work equipment (the pilot lamp in the switch lights up). Set parking brake switch (1) to ON position (A). Apply the parking brake securely. Turn the starting switch to OFF position and stop the en- gine.
Page 302 TRANSPORTATION OPERATION Securing position Fixing angle (A) : 61 ° (B) : 53 ° (C) : 33 ° (D) : 38 ° 3-234...
Page 303 OPERATION TRANSPORTATION Fixed load Front frame: 159000 N {16210 kg} Rear frame: 138000 N {14070 kg} PROCEDURES FOR UNLOADING MACHINE Perform unloading of the machine on a firm, level ground. Maintain a safe distance from the road shoulder Apply the brake of the trailer securely. Set chocks (1) to the front and rear of the tires to secure the trailer.
Page 304: Method For Lifting Machine
This method of lifting applies to the standard specification machine. The method of lifting differs depending on the attachments and options installed. For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor. For the weight, see “SPECIFICATIONS (5-2)”.
Page 305 OPERATION TRANSPORTATION Set the machine horizontally and set the work equipment in the travel posture. For detail, see “METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE, AND SHIFTING GEAR) AND STOPPING MACHINE (3-189)”. (A): 30 cm Check that the work equipment control lever is at HOLD position, then lock the work equipment (the pilot lamp in the switch lights up).
Page 306: Cold Weather Operation
If DEF or the machine equipped with DEF system is stored at the outside temperature lower than -11 °C, DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF, and keep it in the condition free from freezing.
Page 307: Precautions After Daily Work Completion In Cold Weather
OPERATION COLD WEATHER OPERATION BATTERY WARNING • Battery generates flammable gas. Never bring any open flame near fuel. • Battery electrolyte is dangerous object. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor. •...
Page 308: After Cold Weather Season
Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by repeated freeze, ask your Komatsu distributor to inspect. 3-240...
Page 309: Precautions For Long-Term Storage
Start the engine and run it at low idle for 5 minutes. Check for abnormality on the machine monitor and machine. If any abnormality (noise, vibration, etc.) is found, stop the engine immediately, and ask your Komatsu dis- tributor for inspection and maintenance.
Page 310: Starting Machine After Long-Term Storage
If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement. Dispose of drained DEF according to the local regulations and rules.
Page 311: Troubles And Actions
For details of the allowable towing capacity for this machine, see “SPECIFICATIONS (5-2)”. • For details of the procedure for towing a disabled machine, consult your Komatsu distributor. This machine must not be towed except in emergencies. However, if it is avoidable to tow the machine, take the following precautions.
Page 312 TROUBLES AND ACTIONS OPERATION • Keep the angle of the towing rope as small as possible. Keep the angle between the centre lines of the 2 machines to within 30 °. • Usually, use a towing machine of the same class as the machine being towed. Check that the towing ma- chine and towed machine both have ample braking power, and rim pull to allow them to control both ma- chines on slopes or on the tow road.
Page 313 OPERATION TROUBLES AND ACTIONS METHOD FOR RELEASING PARKING BRAKE WITH PARKING BRAKE EMER- GENCY RELEASE VALVE CAUTION When the parking brake switch is OFF (released) and the parking brake emergency release valve is opened, the parking brake is released instantly. Under this condition, even if you feel danger and close the parking brake emergency release valve try- ing to stop the machine, the parking brake does not work immediately.
Page 314 TROUBLES AND ACTIONS OPERATION To restore the function of the parking brake, turn grip (3) of the release valve clockwise to close the release valve, then turn locknut (2) clockwise to lock. Tightening torque Grip (3): 20 ± 5 Nm {2.0 ± 0.5 kgm} Lock nut (2): 20 ±...
Page 315: Precautions For Discharged Battery
The normal gear shifting operation is performed by electric signals. If there should be a failure in the electrical system, and the machine does not move, ask your Komatsu distributor. NOTICE If an emergency travel operation is needed, ask your Komatsu distributor to perform it. PRECAUTIONS FOR DISCHARGED BATTERY WARNING •...
Page 316 TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR REMOVING AND INSTALLING BATTERY Before removing battery, remove the ground cable (nor- mally connected to the negative (-) terminal). If any tool touches the positive terminal of the battery and the chassis, there is a danger that it will cause a spark. Loosen the nuts of the terminal and remove the wires from the battery.
Page 317 OPERATION TROUBLES AND ACTIONS START ENGINE WITH JUMPER CABLES WARNING • When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cable. •...
Page 318: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 319 PHENOMENA AND ACTIONS FOR CHASSIS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 320 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Machine moves slowly and lacks Lack of oil in transmission case Add specified capacity of oil. See power even with engine running at WHEN REQUIRED. full throttle. Clogged screen Disassemble and clean. (*) Oil overheats.
Page 321 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 322 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Indicator of engine coolant tempera- Defective thermostat Replace thermostat. (*) ture gauge does not rise up to the Replace coolant temperature gauge. green range Defective coolant temperature gauge Defective monitor Replace. (*) Starting motor turns but engine does Add fuel.
Page 323 REMARK If no point of contact telephone number is registered, no tele- phone number is displayed. Ask your Komatsu distributor for the telephone number regis- tration if necessary. 3-255...
Page 325: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 326: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 327: Precautions For Kdpf
MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR KDPF When performing inspection and maintenance during or just after regeneration, take care of the high tempera- ture parts. Even after the engine stops the parts around KDPF may be at high temperature. PRECAUTIONS FOR SCR ASSEMBLY Be careful for the high temperature parts when performing inspection and maintenance.
Page 328: Fuel And Lubricants To Match The Ambient Temperature
PRECAUTIONS FOR MAINTENANCE MAINTENANCE • Do not run the engine for long hours with the engine hood open. The engine hood may be damaged by heat of exhaust gas. • Increase the engine speed to check for the leakage of fuel or oil. •...
Page 329: Outline Of Maintenance
• When using commercially available oil, it may be necessary to reduce the oil change interval. We recom- mend that you use the Komatsu oil clinic to check the characteristics of the oil in detail. NOTICE Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu...
Page 330 (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 331 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 332 Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor. STORE OIL AND FUEL • Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
Page 333: Handle Electrical Components
Komatsu recommends installing electric components specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. • When working at the seashore, keep the electrical component clean to prevent corrosion.
Page 334: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 335 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Taper seal Tightening torque Nominal Thread size “a” Width across flats Target value Allowable range No. of hose (mm) “b” (mm) Nm kgm Nm kgm 34 to 63 3.5 to 6.5 59 to 98 6.0 to 10.0 10.5 84 to 132...
Page 336: Maintenance Schedule
MAINTENANCE SCHEDULE MAINTENANCE MAINTENANCE SCHEDULE If the currently used diesel fuel which does not include the bio-fuel is changed to the one mixed with the bio-fuel, the replacement interval of the fuel filter is changed as well. See “MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED (4-13)”.
Page 337: Maintenance Interval When Diesel Fuel Mixed With Bio-Fuel Is Used
MAINTENANCE MAINTENANCE SCHEDULE METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT ............4-58 METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ..........4-59 METHOD FOR CHANGING OIL IN AXLE CASE AND CLEANING AXLE CASE STRAINER ....4-60 METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC AIR FILTERS ........ 4-61 METHOD FOR CHECKING BRAKE DISC WEAR AMOUNT ..............
Page 338 MAINTENANCE SCHEDULE MAINTENANCE Maintenance interval after the diesel fuel has been changed to the diesel fuel mixed with bio-fuel Operating hours of the machine Service meter Every 500 hours Every 1000 hours 250 hours 500 hours Within 500 After 500 op- Within 500 After 500 op- When...
Page 339: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) Perform the following maintenance work only after the first 250 hours of operation on new machines. • Replace transmission oil filter cartridge • Replace hydraulic tank oil filter element For details of the method of replacement or maintenance.
Page 340 MAINTENANCE PROCEDURE MAINTENANCE Clean the element when the yellow piston shown in dust indica- tor (1) display of the air cleaner entered the red (7.5 kPa) posi- tion. After the cleaning, press the dust indicator button to reset it. If the yellow piston enters the red (7.5 kPa) position soon after the cleaning, the element must be replaced.
Page 341 MAINTENANCE MAINTENANCE PROCEDURE Pull air cleaner pull-out jig (3) in a pull-out posture shown in the figure and pull out outer element (4). When pulling out the element, use the air cleaner pull-out jig, hold the handrail tight in one hand, and put your feet on the step to support your body.
Page 342 MAINTENANCE PROCEDURE MAINTENANCE After cleaning, illuminate the inside of the element with an electric bulb to check. If the element has a small hole or thin part, replace it. CAUTION When installing the cover (2), check O-ring (7) for scratches or damages and replace O-ring with a new one if any.
Page 343 MAINTENANCE MAINTENANCE PROCEDURE Install air cleaner pull-out jig (3) to the narrow part of outer element (4). Pull air cleaner pull-out jig (3) in a pull-out posture shown in the figure and pull out outer element (4). When pulling out the element, use the air cleaner pull-out jig, hold the handrail tight in one hand, and put your feet on the step to support your body.
Page 344: Method For Cleaning Inside Of Cooling System
The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 345 When handling the cooling water containing coolant that has been drained during changing the coolant or repairing the radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 346 MAINTENANCE PROCEDURE MAINTENANCE Depress the accelerator pedal (7) lightly and run the en- gine at a medium speed for approximately 5 minutes with no load. 10. Check that the engine rotation has become smoother, then press the work equipment lock switch (8) to release the work equipment lock (pilot lamp goes out).
Page 347: Method For Checking Oil Level In Transmission Case, Adding Oil
MAINTENANCE MAINTENANCE PROCEDURE 14. Open the drain valve (3), drain plugs (4) and (6), then drain the coolant. 15. Close the drain valve (3) and drain plugs (4) and (6). 16. Install the cover (5) on the bottom of the radiator. 17.
Page 348 MAINTENANCE PROCEDURE MAINTENANCE REMARK You cannot measure the exact oil level until 12 hours elapses after the engine is stopped because the oil remains in various parts. Remove the cap of oil filler port (F). Pull out dipstick (G) and wipe the oil off with a cloth. Fully insert dipstick (G) into the dipstick pipe, then remove REMARK Whenever inserting the dipstick, be sure to insert it into the...
Page 349: Method For Checking Oil Level In Axle Case And Adding Oil
MAINTENANCE MAINTENANCE PROCEDURE Check method (1) When User who op- (1) Leave the with engine checking the erates the ma- engine running running at idle oil level after chine continu- at idle for 15 leaving the en- ously (check minutes or gine running at during lunch more and (2)
Page 350: Method For Cleaning Axle Breather
MAINTENANCE PROCEDURE MAINTENANCE Stop the engine and remove plug (1). Wipe off oil of dipstick (G) installed to plug (1) by using a piece of cloth. Set dipstick (G) as shown in the figure. (2): Axle (3): Spot facing surface The level is appropriate if it is between 2 grooves (H) and (L) of the dipstick.
Page 351: Method For Cleaning Air Conditioner Condenser
MAINTENANCE MAINTENANCE PROCEDURE Remove mud and dust around the breather by using a brush, etc. Remove the breather, immerse it in detergent liquid, and clean it. • Clean the breathers in 2 locations, the front and rear sides. • While the breather is removed, use care to prevent entry of dusts through the mounting location of the breather.
Page 352: Method For Cleaning Fins By Rotating Cooling Fan In Reverse
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING FINS BY ROTATING COOLING FAN IN REVERSE NOTICE When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth, etc. will not be wound in the fan. Since dust may be blown up, check that there is no people around while the fan is rotating in reverse.
Page 353 MAINTENANCE MAINTENANCE PROCEDURE Press down lever (2) and open fan guard (3). Blow off mud, dirt, leaves, etc. in radiator fins (4) with com- pressed air. NOTICE Steam or water may be used instead of the com- pressed air. However, when using the powerful steam cleaning equipment (high-pressure machine wash) for the heat exchange equipment (radiator and cooler), keep a suf- ficient distance to the target machine.
Page 354: Method For Inverting And Replacing Bolt On Cutting Edge
MAINTENANCE PROCEDURE MAINTENANCE For soil and dust fallen down, blow them out of the machine according to the following procedure. Loosen wing bolts (4) (2 pieces), and slide covers for cleaning (5) on the right and left sides of the machine, and open those covers.
Page 355 MAINTENANCE MAINTENANCE PROCEDURE Raise the bucket to a suitable height, then put a block (A) under the bucket to prevent the bucket from lowering. Raise the bucket to make its bottom surface level. Remove the bolts and nuts (1) and (2), and remove bucket teeth (3).
Page 356 MAINTENANCE PROCEDURE MAINTENANCE Push out pin (1) to the direction of arrow by hand or ham- mer, and remove tooth (2). Check the torque to unlock the pin by using torque wrench according to the following procedure. Rotate the shaft of pin (1) with torque wrench, and set it to the lock state (90 °).
Page 357: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID Check the water level in window washer tank (1), and if it is in- sufficient, add the window washer fluid for automobiles. Be careful not to let dirt or dust get in when adding fluid. METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER METHOD FOR CHECKING LEVEL OF REFRIGERANT (GAS) WARNING...
Page 358: Method For Replacing Slow-Blow Fuse
MAINTENANCE PROCEDURE MAINTENANCE Start the engine and set the engine speed to approximate- ly 1500 rpm. Press fan switch (1) and set the air flow to “Hi”. Press temperature adjustment switch (2) and set the tem- perature to 18 °C. Fully open the doors and windows. Press air conditioner switch (3) to turn the air conditioner switch ON.
Page 359: Method For Checking Function Of Ecss Accumulator
If there is no change in the vertical motion between the 2 settings, the accumulator gas pressure has proba- bly dropped. Ask your Komatsu distributor for inspection. REMARK The inspection must be performed with the gear speed of the 2nd to the 4th, and with the travel speed of 5 km/h or faster.
Page 360: Select And Check Tires
• If a tire not specified by Komatsu is used, rim displacement between the tire and rim may occur. Operator comfort, as well, may be degraded. Maximum load [ kg ]...
Page 361: Method For Cleaning And Replacing Fuel Breather Filter
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING AND INFLATING TIRE WARNING • When pumping up the tires, check that no other person is standing near the tire, and install an air chuck with a clip that can be secured to the air valve. •...
Page 362: Method For Lubricating Rear Full-Length Fender Hinge
MAINTENANCE PROCEDURE MAINTENANCE Open the engine side cover on the left side of the ma- chine. Loosen nut (2) at the top of fuel breather (1) which is loca- ted left upper of fan guard and remove it. Turn cover (3) counterclockwise and remove it. Remove element (4) upwards.
Page 363: Checking Auto-Greasing And Operation Method For Filling Grease
Komatsu distributor. Maintenance work should be performed if needed or every 50 hours. If any problem occurs, consult your Komatsu distributor. Prepare the grease. For the types of grease, see “METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
Page 364: Checks Before Starting
MAINTENANCE PROCEDURE MAINTENANCE • Check the general control function according to the following procedure. Start the manual lubrication mode. Check the function of the control unit and system components. • Check the system components for leakage and damage. Perform the check periodically. •...
Page 365: Every 50 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE • Check the wheel rims • Check the rearview monitor “METHOD FOR CHECKING BEFORE STARTING (3-159)” • Method For Checking Water Separator, Draining Water And Sediment • Method For Checking Coolant Level, Adding Coolant • Method For Checking Oil Level In Engine Oil Pan, Adding Oil •...
Page 366: Method For Checking Oil Level In Hydraulic Tank, Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 367: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Insert the starting switch into key lock (1) and release the lock. Pull the key and open cover (2). REMARK If the cover does not open easily by turning the key, push the cover with your hand to facilitate its opening. Take out filter (3) and clean it.
Page 368 LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu dis- tributor or a battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO...
Page 369: Method For Testing Parking Brake
If the purified water is added to above the bottom of the sleeve, use a syringe to remove electrolyte. Neu- tralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 370 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR TESTING WHEN AIR CONDITIONER COMPRESSOR BELT IS RE- PLACED Press the middle point between the compressor pulley and crankshaft pulley with your thumb (approximately 98 N {10 kg} ). The standard deflection is 22 to 23 mm. When you use a belt tension gauge, the tension is normal if it is in the range of 540 to 637 N {55 to 65 kg} . REMARK When the belt is replaced with a new one, the above value is employed as the initial tension since a stronger tension is required.
Page 371: Method For Checking Looseness Of Wheel Hub Bolts, Retightening Bolts
MAINTENANCE MAINTENANCE PROCEDURE NOTICE • Check each pulley for damage, wear of the V-groove, and the wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove. • Replace the belt with a new one if the belt is stretched and has no allowance for adjustment, or has slipping sound or squeak because of cuts or cracks of the belt.
Page 372: Every 500 Hours Maintenance
• If the brake oil pressure caution lamp lights up when the brake pedal is depressed 5 times or less, the gas pressure in the accumulator may be low. Ask your Komatsu distributor for inspection. REMARK The inspection must be done within 5 minutes after the engine stops. If the engine is kept stopped, the gas pressure in the accumulator lowers and the inspection cannot be made.
Page 373: Method For Replacing Fuel Prefilter Cartridge
Loosen drain valve (P) and drain the oil. Check the drained oil. If it contains much metallic powder or foreign material, contact your Komatsu distributor. Tighten drain plug (P). Turn filter cartridge (1) counterclockwise by using the filter wrench, and remove it.
Page 374 The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 375: Every 1000 Hours Maintenance
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 376 MAINTENANCE PROCEDURE MAINTENANCE Open the engine side cover on the right side of the ma- chine. Place a container under the filter cartridge to catch the fuel. Turn filter cartridge (1) counterclockwise by using the filter wrench, and remove it. Clean the filter head.
Page 377: Method For Changing Oil In Transmission Case And Cleaning Transmission Case Strainer
MAINTENANCE MAINTENANCE PROCEDURE Turn fuel feed pump switch (2) under the fuel prefilter car- tridge to ON position. Lamp (3) flashes and the fuel feed pump operates. After the specified time (approximately 7 minutes), lamp (3) goes out automatically and the fuel feed pump stops. When lamp (3) goes out, air bleeding is completed.
Page 378: Method For Replacing Transmission Oil Filter Cartridge
MAINTENANCE PROCEDURE MAINTENANCE Place a container under drain plug (2) to catch the oil. Remove drain plug (2), and loosen plug (3) to drain the oil. Loosen drain plug (3) gradually so that the oil will not spout out, and then remove it. After draining the oil, tighten drain plug (2) and plug (3).
Page 379: Method For Cleaning Transmission Breather
MAINTENANCE MAINTENANCE PROCEDURE Place a container under the transmission filter to catch the oil. Remove transmission filter plug (3). Drain the oil, then tighten the plug. Turn transmission filter cartridge (4) counterclockwise by using nut (5) welded to transmission filter cartridge (4) and remove it.
Page 380: Every 2000 Hours Maintenance
MAINTENANCE METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. METHOD FOR CHECKING AND REPLACING ALTERNATOR BELT •...
Page 381 MAINTENANCE MAINTENANCE PROCEDURE Loosen the bolts and remove cover (2). Remove the cap of oil filler port (F). Place a container under drain plug (3) to catch the drained oil. Remove drain plug (3). Open drain valve (4) gradually to drain the oil. After draining the oil, close drain valve (4) and tighten drain plug (3).
Page 382: Method For Replacing Hydraulic Oil Filter Element
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 383: Method For Replacing Hydraulic Tank Breather Element
MAINTENANCE MAINTENANCE PROCEDURE 10. Extend and retract each of the steering, bucket, and boom cylinders to the stroke end 3 to 4 times. 11. Stop the engine, then loosen air bleeding plug (7). 12. After bleeding air from the hydraulic tank, tighten plug (7). 13.
Page 384: Method For Changing Oil In Axle Case And Cleaning Axle Case Strainer
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHANGING OIL IN AXLE CASE AND CLEANING AXLE CASE STRAINER WARNING • When changing the oil, apply the parking brake and secure the front and rear frames with the frame lock bar. • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 385: Method For Replacing Air Conditioner Fresh/Recirc Air Filters
MAINTENANCE MAINTENANCE PROCEDURE Remove the hoses (4) (3 pieces). Remove the cap and remove the strainers (5) (3 pieces). Loosen the bolts (6) (4 pieces) and remove the cover (7). 10. Remove the hoses (8) (1 piece). 11. Remove the cap and remove the strainers (9) (1 piece). 12.
Page 386: Method For Checking Brake Disc Wear Amount
Allowable disc wear limit (B) corresponds to the distance between groove (E) and end face (D) of the guide. In such case, ask your Komatsu distributor to perform in- spection and replacement of the part. If the disc wear approaches the wear limit, check the con- dition frequently, regardless of the maintenance interval.
Page 387: Method For Checking Alternator
If the engine is started frequently, have this inspection performed every 1000 hours. METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. METHOD FOR CHECKING VIBRATION DAMPER Check that there are no cracks or peeling in the outside surface of the rubber.
Page 388 MAINTENANCE PROCEDURE MAINTENANCE Items to be prepared • Container to catch drained oil • Special wrench for KCCV The KCCV ventilator is located in the positions shown in the figure. For the use of the special wrench, see the figure. By using the special wrench, loosen ring (3) of KCCV ven- tilator (1).
Page 389 MAINTENANCE MAINTENANCE PROCEDURE Apply engine oil to the new O-ring. While matching ◇ marks (7) of the new element with ◇ mark (8) of the body label, insert the element thoroughly into the end of the body. The element can be installed only when its claws (9) are correctly inserted in grooves (10) of the filter body.
Page 390: Method For Replacing Def Filter
Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without DEF filter attached, or with the filter other than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine.
Page 391 MAINTENANCE MAINTENANCE PROCEDURE The DEF filter is located at the positions shown in the figure. Remove filter cap (1) at the bottom of DEF pump, and re- move equalizing element (2). Turn cap (4) of filter removal tool (3) and remove it. Check the installation of spacer (5).
Page 392: Method For Replacing Def Tank Breather Element
MAINTENANCE PROCEDURE MAINTENANCE Turn filter removal tool (3) in reverse, and remove filter (6). Filter (6) is removed and you can take it out together with filter removal tool (3). If filter (6) cannot be removed from DEF pump, grip filter removal tool (3), pull it down, then it will be removed.
Page 393 If the machine is operated without DEF tank breather element attached, or with the element other than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine. Never operate the machine without DEF tank breather element at- tached, nor use the element other than Komatsu genuine parts.
Page 394: Method For Replacing Def Tank Filler Port Filter
Wait until all of parts cool down before starting the work. NOTICE • If the filter other than Komatsu genuine parts is used, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine. Komatsu recommends using Komatsu genuine parts for replacement parts.
Page 395: Every 4000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE When installing the DEF tank filler (3), take care about the direction. 10. Install the bolts (2) (4 pieces). Tightening torque: 9.5 to 10.5 Nm {0.97 to 1.07 kgm} 11. Align the claw (6) of cap (1) with groove (7) of the filler port and close the cap securely by turning it clockwise by 90 °.
Page 396: Method For Lubricating Drive Shaft
Work equipment hydraulic Main pump delivery hose system Main pump delivery hose other than described above Ask your Komatsu distributor Main pump LS hose for replacement. Hydraulic drive fan hose (Intake fan) Hydraulic drive fan hose (Exhaust fan) External work equipment hose Lift cylinder hose •...
Page 397 MAINTENANCE MAINTENANCE PROCEDURE Viewed from the rear side of the machine. 4-73...
Page 398: Method For Checking Water Pump
Viewed from the rear side of the machine. METHOD FOR CHECKING WATER PUMP Check for leakage of water and oil around the water pump. If any problem is found, ask your Komatsu distributor to perform disassembly, repair, or replacement. METHOD FOR CHECKING STARTING MOTOR Ask your Komatsu distributor to have the starting motor checked.
Page 399: Method For Checking For Looseness Of Engine High-Pressure Piping Clamp, Hard- Ening Of Rubber
Check clamps (1) to (14) visually and with your fingers that there are no loose bolts or hardening of the rubber. If there are any problems, the related parts must be replaced. Ask your Komatsu distributor for replacement. METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP,...
Page 400: Every 4500 Hours Maintenance
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING, HARDENING OF RUBBER Ask your Komatsu distributor to have the fuel spray prevention cap on fuel doser checked. EVERY 8000 HOURS MAINTENANCE Maintenance for every 50, 100, 250, 500, 1000, 2000 and 4000 hours service should be performed at the same time.
Page 401: Every 9000 Hours Maintenance
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING Ask your Komatsu distributor for replacement of the fuel spray prevention cap on fuel doser. END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. 4-77...
Page 403: Specifications
SPECIFICATIONS...
Page 404: Specifications: Wa480-8
(with bolt on cutting edge (BOC)) Normal load kg 7820 Bucket capacity Heaped m Engine model KOMATSU SAA6D125E-7 diesel engine SAE J1995 (gross) 224 {301} / 2000 {2000} kW {HP} / Rated horsepower ISO 14396 224 {301} / 2000 {2000} {rpm}...
Page 405 SPECIFICATIONS SPECIFICATIONS *1: Value when bucket dump angle is 45°. 9 J W 0 1 4 5 6...
Page 407: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 408: Bucket And Tire Selection
Spade nose rock bucket (3.6 m 26.5-25-20PR (L3: Rock) 26.5R25XHA2 Soft ground with many large boulders 26.5-25-20PR (L3: Rock) BOC: Abbreviation for Bolt On Cutting edge The speed display varies with the tire size. When installing optional tires, ask your Komatsu distributor for instal- lation.
Page 409: Handle Multifunction Mono-Lever
ATTACHMENTS AND OPTIONS HANDLE MULTIFUNCTION MONO-LEVER HANDLE MULTIFUNCTION MONO-LEVER EXPLANATION OF EQUIPMENT ON MULTIFUNCTION MONO-LEVER (1) Multifunction mono-lever (4) Multifunction mono-lever directional selector switch (2) Kickdown switch (5) PCS (Proportional Control Switch) (3) Hold switch MULTIFUNCTION MONO-LEVER The multifunction mono-lever is used to operate the boom and bucket.
Page 410: Kickdown Switch
HANDLE MULTIFUNCTION MONO-LEVER ATTACHMENTS AND OPTIONS Position (a): RAISE When the multifunction mono-lever is pulled further from the “RAISE” position, the lever stops in that position. When the remote boom positioner is enabled, the boom stops at the preset position and the lever returns to “HOLD” position at the same time.
Page 411: Hold Switch
ATTACHMENTS AND OPTIONS HANDLE MULTIFUNCTION MONO-LEVER This function facilitates the load-and-carry operation. When the travel speed is 12 km/h or higher, each time the kickdown switch is pressed, the gear speed is shifted down by one gear speed in the order F4, F3, and F2. REMARK •...
Page 412: Pcs(Proportional Control Switch)
HANDLE MULTIFUNCTION MONO-LEVER ATTACHMENTS AND OPTIONS You can select FORWARD, NEUTRAL, or REVERSE with the multifunction mono-lever directional selector switch. The basic operation is as follows. Position (F): FORWARD Position (N): NEUTRAL Position (R): REVERSE Before using this switch to change the travel direction, set the directional lever to NEUTRAL position and set directional se- lector enable switch (A) of R.H.
Page 413: Lcd Unit
ATTACHMENTS AND OPTIONS HANDLE MULTIFUNCTION MONO-LEVER Continuous mode When switch is operated to the limit of position (C), the set maximum flow is held and the third attachment continues the operation even if the switch operation is stopped. This action is called the detent control.
Page 414: Oil Flow Control Mode Pilot Lamp (Proportional Oil Flow Mode)
HANDLE MULTIFUNCTION MONO-LEVER ATTACHMENTS AND OPTIONS OIL FLOW CONTROL MODE PILOT LAMP (PROPORTIONAL OIL FLOW MODE) The flow control mode pilot lamp (proportional mode) lights up when the flow control of PCS is in the proportional mode. DETENT OPERATION PILOT LAMP The detent operation pilot lamp lights up when the detent con- trol is performed in the continuous mode.
Page 415: Method For Setting Pcs
ATTACHMENTS AND OPTIONS HANDLE MULTIFUNCTION MONO-LEVER METHOD FOR SETTING PCS Press menu switch (1) and enter the setting mode. Select “Attachment Setting” on “Machine Setting or Infor- mation” menu, and press ENTER switch (2). If the flow rate mode and maximum flow rate are set al- ready, select any setting, and the setting is completed.
Page 416 HANDLE MULTIFUNCTION MONO-LEVER ATTACHMENTS AND OPTIONS If you select “Attachment Name” and press menu switch (1), you can delete the setting name or return it to the de- fault value. Select “Flow Control Mode”, and press ENTER switch (2). You can select “Proportional Mode” or “Continuous Mode”. Select “Attachment Flow”, and press ENTER switch (2).
Page 417: Seat Heater And Seat Ventilation
ATTACHMENTS AND OPTIONS SEAT HEATER AND SEAT VENTILATION SEAT HEATER AND SEAT VENTILATION (only machine with three-point seat belt) CAUTION • Using the heater for a long time may cause low temperature burn (blister, etc.). • Do not put a heavy luggage on the cushion. Do not stick the cushion with needles, nails, etc. •...
Page 418: Method For Using Seat Ventilation
SEAT HEATER AND SEAT VENTILATION ATTACHMENTS AND OPTIONS METHOD FOR USING SEAT VENTILATION Set the seat heater and ventilation selector switch (1) to the ventilation position (b). Set the air flow control switch (2) to HIGH position (d) or LOW position (e). The ventilator operates, and air blows out from the cushion seat and backrest.
Page 419: Handle Seat Belt
ATTACHMENTS AND OPTIONS HANDLE SEAT BELT HANDLE SEAT BELT (three-point seat belt) METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. •...
Page 420 HANDLE SEAT BELT ATTACHMENTS AND OPTIONS METHOD FOR CONNECTING SHOULDER BELT AND WAIST BELT Insert the tongue (2) of the shoulder belt into the buckle tongue (1) of the waist belt. Rotate the tongue (2) of the shoulder belt and make sure that it is securely fixed to the buckle tongue (1) of the waist belt.
Page 421 ATTACHMENTS AND OPTIONS HANDLE SEAT BELT METHOD FOR ADJUSTING SEAT BELT ANCHOR Move the seat belt anchor up and down to adjust it to the de- sired height. Adjustment amount: 100 mm Number of stages for adjustment: 6 stages Adjustment amount per 1 stage: 20 mm 6-15...
Page 423: Replacement Parts
REPLACEMENT PARTS...
Page 424: Periodic Replacement Of Defined Life Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. DEFINED LIFE PARTS LIST Periodical replacement parts...
Page 425: Consumable Parts
The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
Page 426: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 427 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT The symbols used in the lubrication chart are explained as follows. Symbol Meaning of the symbol Symbol Meaning of the symbol Read the Operation and Maintenance Greasing of the grease Manual. Change of the engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level...
Page 428: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
Cooling system AF-NAC (KES) AF-NAC (Note.5) EN 590 Class 2 Fuel tank Diesel fuel EN 590 Grade D DEF tank DEF (Note.6) Air conditioner Refrigerant R134a (HFC134A) KES: Komatsu Engineering Standard Specified capacity Refill capacity Reservoir Liter Liter Engine oil pan...
Page 429 Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems in the cooling system, including the engine.
Page 430: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
Page 431: Index
INDEX INDEX Symbols Alternator - Check..........4-63 Alternator belt - Check / Replace......4-56 12/24 display mode..........3-85 Always use clean washer fluid........ 4-2 2-stage low idle setting......... 3-66 Appoint leader when working with others..... 2-32 2-stage low idling pilot lamp........3-34 Armrest angle - Adjust........
Page 432 INDEX Bucket level indicator.......... 3-206 DEF hose - Replace..........4-77 Bucket level position - Select........ 3-67 DEF level - Check..........3-206 Bucket teeth - Replace..........4-30 DEF level caution lamp......... 3-21 DEF level gauge........... 3-45 DEF low level guidance........3-41 DEF system caution lamp........3-26 Cab door - Open / Close........3-111 DEF system high-temperature stop caution lamp.3-26 Cab door handle..........3-112...
Page 433 INDEX End of service life......... 2-33,4-77 Fan switch............3-223 Energy saving guidance........3-51 Filter................ 4-8 Engine - Check low-speed run and acceleration 3-186 Fin - Clean by rotating cooling fan in reverse..4-28 Engine - Check starting condition and unusual noise.. Fin - Clean with compressed air......4-28 ..............3-185 Fins - Open engine side cover / Clean....4-29 Engine - Operate / Check after starting....
Page 434 KMAX tooth - Replace.......... 4-31 Machine - Warm up..........3-186 Komatsu Closed Crankcase Ventilation (KCCV) 3-138 Machine equipment name........3-2 Komatsu Diesel Particulate Filter (KDPF) - Handle..Machine monitor - Check........3-168 ..............3-130 Machine monitor - Display when starting engine while Komatsu genuine lubricants........4-2 engine shutdown secondary switch is ON..
Page 435 Maintenance of air conditioner......2-39 PCS - Set..............6-9 Maintenance procedure........4-15 PCS (Proportional Control Switch)......6-6 Maintenance schedule.......... 4-12 Perform KOWA (Komatsu Oil Wear Analysis)..4-7 Maintenance schedule table......... 4-12 Periodic replacement of defined life parts.....2-40 Maintenance time caution lamp......3-29 Permissible water depth........3-205 Manual operation..........
Page 436 INDEX Precautions for jobsite.......... 2-21 Rear full-length fender and engine side cover - Open. Precautions for KDPF..........4-3 ..............3-120 Precautions for long-term storage.......3-241 Rear full-length fender and engine side cover - Open Precautions for maintenance......2-32,4-2 and close............. 3-120 Precautions for noise..........2-39 Rear full-length fender hinge - Lubricate....4-38 Precautions for operation....
Page 437 Transmission oil filter cartridge - Replace..... 4-54 Slow-blow fuse - Replace........4-34 Transmission serial plate location......1-15 Specifications............5-2 Transmission shift mode selector switch.....3-102 Specifications - WA480-8........5-2 Transmission system caution lamp....... 3-24 Speedometer............3-41 Transportation............. 3-232 Stability..............2-32 Travel downhill............ 3-205 Standard tightening torque for bolts and nuts..
Page 438 INDEX When handling accumulator and gas spring..2-39 When operating on snow or frozen ground...2-29 When required............4-15 Window washer fluid - Check level / Add....4-33 Window washer fluid - select........ 2-40 Window washer fluid spouting out - Check..3-168 Wiper function - Check........3-168 Work equipment - Operate........3-201 Work equipment lock pilot lamp......
Page 440 WA480-8 WHEEL LOADER Form No. VENAM51500 ©2018 KOMATSU All Rights Reserved Printed in Europe 07-2018...

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