Komatsu WA470-6 2006 Operation & Maintenance Manual
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Komatsu WA470-6 2006 Operation & Maintenance Manual

Wheel loader
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Operation & Maintenance
Manual
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept near the machine
for reference and periodically reviewed by all personnel
who will come into contact with it.
NOTICE
Komatsu has had the operating and maintenance in-
structions translated into all the languages of the mem-
ber states in the European Union. Should you wish to
have a version of the operating instructions in another
language, please don’t hesitate to ask at your local
dealer’s.
© 2006 Komatsu Hanomag GmbH
All Rights Reserved
Printed in Europe 10-2006
WARNING
WA470-
WHEEL LOADER
H50051
SERIAL NUMBERS
VEAM946100
and up
6

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  • Page 1 NOTICE Komatsu has had the operating and maintenance in- structions translated into all the languages of the mem- ber states in the European Union. Should you wish to have a version of the operating instructions in another language, please don’t hesitate to ask at your local...

  • Page 3: Foreword

    Foreword 1. Foreword WA470-6H – VEAM946100...

  • Page 4: Foreword

    If you sell the machine, be sure to give this manual to the new owners together with the machine. KOMATSU delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in...

  • Page 5: Eu Directives

    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 instruc- tions for wiring, installation and maximum permitted power con- sumption. WA470-6H – VEAM946100...

  • Page 6: Safety Information

    1.2 Safety information Foreword Safety information To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations. 1.2.1 Signal words The following signal words are used to inform you that there is a...
  • Page 7 Foreword 1.2 Safety information Other signal words In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is useful to know. NOTE This word is used for precautions that must be taken to avoid actions which could shorten the life of the machine.

  • Page 8: Safety Labels

    Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult KOMATSU or your KOMATSU distributor for the latest available information of your machine or for questions regarding information in this manual.

  • Page 9: Introduction

    Driving in forward direction, the loader can load or dig material using its attachments intended for loading operations (i.e. bucket). This KOMATSU machine is designed to be used mainly for the following work: Digging work Smoothing...

  • Page 10: Directions Of Machine

    1.3 Introduction Foreword 1.3.2 Directions of machine Front Bucket Left Right Rear GK032003 In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the operator's seat in the direction of travel (front) of the machine. 1.3.3 Visibility from operator's seat The visibility standards (ISO 5006) for this machine require a...
  • Page 11 Foreword 1.3 Introduction 12-M Radius visibility The visibility at a radius of 12 m from the machine is as shown in the diagram below. The hatched areas (B) show the areas where the view is blocked when mirrors or other aids to visibility are installed as standard.

  • Page 12: Necessary Information

    1.4 Necessary information Foreword Necessary information When requesting service or ordering replacement parts, please inform your KOMATSU distributor of the following items. 1.4.1 Product Identification Number (PIN)/Machine serial no. plate and position On the center right of the front frame.

  • Page 13: Rops/Fops-Cab Serial No. Plate

    Foreword 1.4 Necessary information 1.4.3 ROPS/FOPS-Cab serial no. plate This plate is located on the right inside cab on the rear beam. WARNING GK032006 1.4.4 Axle serial no. plate This plate is located on the right of front axle and on the left of rear axle.

  • Page 14: Seat Operator Serial No. Plate

    1.4 Necessary information Foreword 1.4.6 Seat operator serial no. plate This plate is located in front of seat, covered by the bellows. GK032009 1.4.7 Position of service meter The service meter is displayed on the character display at the bottom center of the machine monitor. GK038005 1.4.8 Table to enter serial no.

  • Page 15: Table Of Contents

    Foreword 1.5 Contents Contents Foreword ........... . . 1-1 Foreword .

  • Page 16: Contents

    1.5 Contents Foreword Operation ........... . . 3-1 General view .
  • Page 17 Foreword 1.5 Contents Operation ..............3-88 3.3.1 Check before starting engine, adjust .
  • Page 18 1.5 Contents Foreword 3.3.15 Handling the tires........... . . 3-146 Precautions when handling tires .
  • Page 19 Grease ............. 4-10 Carrying out KOWA (KOMATSU Oil Wear Analysis) ......4-10 Storing oil and fuel .
  • Page 20 1.5 Contents Foreword Check air conditioner........... 4-49 Replace slow blow fuse .
  • Page 21 Foreword 1.5 Contents 4.9.13 Every 8000 hours service..........4-89 Replace high-pressure piping clamp .
  • Page 22 1.5 Contents Foreword Index ............7-1 Index .

  • Page 23: Dimensions, Weights And Operating Data

    Foreword 1.6 Dimensions, weights and operating data Dimensions, weights and operating data 1.6.1 WA470-6H: Dimensions, weights and operating data GK047071 Measurements, operating data Bucket capacity to ISO 7546 m³ without teeth and without BOC Material density t/m³ Bucket weight without teeth 1,860 Static tipping load, straight 18,710...

  • Page 24: Ce-Conforming Equipment

    1.7 CE-Conforming equipment Foreword CE-Conforming equipment 1.7.1 CE-Conforming equipment CE-Conforming equipment – Hydraulic Volume Load Capacity Weight Type Part No. pressure m³ 421-75-H2760 4.35 7,830 2,030 421-75-H2770 4.35 7,830 2,185 421-75-H2780 8,100 2,260 421-75-H2790 4.35 7,830 2,135 421-75-H2800 4.35 7,830 2,290 421-75-H2810 8,100...

  • Page 25: Manufacturer-Supplied Ce-Conforming Equipment, According To

    Foreword 1.7 CE-Conforming equipment 1.7.2 Manufacturer-supplied CE-Conforming equipment, according to document 419-93-H1250 The responsibility for observing valid regulations in the case of wheel loaders with "interchangeable equipment" (e.g. bucket or fork-lift) which was not supplied from works lies with the cus- tomer which was subsequently fitted to the machine.
  • Page 26 1.7 CE-Conforming equipment Foreword d1=d2 GK032014 1-24 WA470-6H – VEAM946100...
  • Page 27 Foreword 1.7 CE-Conforming equipment Manufacturer- supplied CE-Conforming equipment, accord- ing to document 419-93-H1250 WA470-6H 419-93-H1250 2,245 Distance: bucket pivoting point - front axle, horizontal 1,345 Distance: bucket pivoting point - front axle, vertical Distance: road level - front axle 2,100 Distance: driver's eye (1) - front axle, horizontal 2,215 Distance: driver's eye (1) - front axle, vertical...
  • Page 28 1.7 CE-Conforming equipment Foreword 1-26 WA470-6H – VEAM946100...

  • Page 29: Safety

    Safety 2. Safety WARNING Please read and make sure that you fully understand the precautions described in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly. WA470-6H – VEAM946100...

  • Page 30: Safety Labels

    For details of the part numbers, see this manual or check on the actual part, and order the new part from your KOMATSU distributor. There are also other labels in addition to the safety labels. Han- dle these labels in the same way.

  • Page 31: Presentation Of Safety Labels

    Safety 2.1 Safety labels 2.1.2 Presentation of safety labels GK032020 GK032018 GK032021 GK032019 GK032023 GK032024 GK032022 GK032025 GK032026 GK032027 GK032028 GK032030 19, 20 WA470-6H – VEAM946100...
  • Page 32 2.1 Safety labels Safety GK032020 GK032018 GK032021 GK032019 GK032023 GK032024 GK032022 GK032025 GK032026 GK032027 GK032028 GK032030 19, 20 WA470-6H – VEAM946100...
  • Page 33 Sign indicates to prevere severe injury or death. Honk to alert people nearby. Be sure no one is on or near machine. Use spotter if view is obstructed. Use KOMATSU oil only (421-93-H1390) Do not enter (421-93-H1320) Sign indicates a crush hazard between the articulating parts of the vehicle. Keep away from the vehicle when it is move.
  • Page 34 2.1 Safety labels Safety Caution for high temparture exhaust pipe (09817-A0753) Sign indicates a burn hazard from touching heated parts, such as engine, motor, or muffler during or right after operation. Never touch when hot. Caution for common rail high pressure (6217-71-9331) Parking brake emergency cancel valve (423-93-41172) Escape (425-93-51110) WA470-6H –...

  • Page 35: General Precautions

    Safety 2.2 General precautions General precautions Safety rules Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be sev- erly impaired putting yourself and everyone else on your job- site in danger.
  • Page 36 2.2 General precautions Safety Fire extinguisher and first aid kit Always follow the precautions below to prepare for action if any injury or fire should occur. The fire extinguisher can be fastened to the inside cabin wall on the left. If, in the course of certain operations, there is danger of fire, fire extinguishers must be at hand.
  • Page 37 Safety 2.2 General precautions Inside operator's compartment When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious acci- dent.
  • Page 38 2.2 General precautions Safety Handrails and steps To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the dia- gram on the right when getting on or off the machine. To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps to ensure that you...
  • Page 39 Safety 2.2 General precautions Precautions when cleaning cab glass It is extremely dangerous to cross from the side of the cab to the step on the front fender. Always articulate the machine fully to the side, then cross on that side from the side of the cab to the step,.
  • Page 40 2.2 General precautions Safety Do not get caught in articulated portion If the clearance at the articulating portion changes, it will lead to serious personal injury. Do not allow anyone to come inside the articulation range. Never enter or put your hand, arm, or any part of your body in the movable portion between the work equipment and machine or between the cylinder and the work equipment.
  • Page 41 Safety 2.2 General precautions Fire prevention Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particu- larly flammable and can be hazardous. To prevent fire, always observe the following: Do not smoke or use any flame near fuel or oil. "...
  • Page 42 2.2 General precautions Safety Fire coming from hydraulic line Check that all the hose and tube clamps, guards, and cush- ions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the hoses, and cause high-pressure oil to spurt out, leading to fire dam- age or serious injury.
  • Page 43 Unauthorized modification If this machine is modified without permission from KOMATSU, there is danger that problems may occur with safety and that this may lead to serious personal injury. Modifications may have an adverse effect on items such as machine strength and visibility.
  • Page 44 2.2 General precautions Safety Safety at worksite Before starting operations, thoroughly check the work area for dangerous working conditions. Inspect the surface of the soil in the working area and deter- mine the optimum and safest procedure. When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating.
  • Page 45 Safety 2.2 General precautions Do not go close to high-voltage cables Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows.
  • Page 46 2.2 General precautions Safety Ensure good visibility This machine is equipped with mirrors to improve the visibility, but even with mirrors, there are places, which cannot be seen from the operator's seat, so always be careful when operating. When operating or traveling in places with poor visibility, if it is impossible to confirm the condition of the job side or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator may suffer serious...
  • Page 47 Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine KOMATSU parts. 2-19 WA470-6H – VEAM946100...

  • Page 48: Precautions For Operation

    2.3 Precautions for operation Safety Precautions for operation 2.3.1 Starting engine If there is a warning tag hanging from the work equipment con- trol lever, do not start the engine or touch the levers. Checks before starting engine Carry out the following checks before starting the engine at the beginning of the day's work.
  • Page 49 Safety 2.3 Precautions for operation Precautions when starting Start and operate the machine only while seated. Never try to start the engine by hot-wiring the ignition. This can cause fire, grave injuries or death. Do not attempt to start the engine by short-circuiting the engine starting circuit.

  • Page 50: Operation

    2.3 Precautions for operation Safety 2.3.2 Operation Checks before operation When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check the operation of travel, steering and brake systems, and work equipment control system.
  • Page 51 This may cause the tires to burst. If a tire bursts, it produces an extremely large destruc- tive force, and this may cause serious injury or accident. If you are going to travel continuously, please consult your KOMATSU distributor. 2-23 WA470-6H – VEAM946100...
  • Page 52 2.3 Precautions for operation Safety Traveling on slopes To prevent the machine from tipping over or slipping to the side, always do as follows. When traveling on slopes, keep the bucket at height “A“ of approximately 200 to 300 mm (8 to 12 in) above the ground. In case of emergency, quickly lower the bucket to the ground to help the machine to stop.
  • Page 53 Safety 2.3 Precautions for operation Prohibited operations It is dangerous to excavate the bottom of a rock face. Never do this. When digging, never thrust the bucket into a load at an angle. This will bring an excessive load to bear on the machine and will reduce the service life of the machine.
  • Page 54 2.3 Precautions for operation Safety Precautions when operating When using the machine, to prevent the machine from over- turning due to overloading and to avoid damage to the work equipment, do not exceed the maximum permitted load or performance of the machine. If the engine cannot be started again after it has stopped, immediately operate the work equipment control levers to lower the work equipment to the ground.
  • Page 55 Safety 2.3 Precautions for operation When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, be extremely careful not to let the work equipment hit anything. To prevent accidents caused by hitting other objects, always operate the machine at a speed which is safe for operation, particular in confined spaces, indoors, and in places where there are other machines.
  • Page 56 2.3 Precautions for operation Safety Parking machine Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground. GK032064 When leaving the machine, set work equipment lock lever (1) to the LOCK position and parking brake switch (2) to the...

  • Page 57: Transportation

    Transportation The machine can be divided into parts for transportation, so when transportating the machine, please contact your KOMATSU distributor to have the work carried out. Loading and unloading When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
  • Page 58 2.3 Precautions for operation Safety Shipping When shipping the machine on a trailer, do as follows. The weight, transportation height, and overall length of the machine differ according to the work equipment, so be sure to confirm the dimensions. When passing over bridges or structures on private land, check first that the structure is strong enough to support the weight of the machine.

  • Page 59: Battery

    Safety 2.3 Precautions for operation 2.3.4 Battery Battery hazard prevention Battery electrolyte contains sulphuric acid, and batteries gener- ate flammable hydrogen gas, which may explode. Mistaken han- dling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line.
  • Page 60 2.3 Precautions for operation Safety Starting with booster cables If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as fol- lows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the opera- tor's seat and the other working with the battery).

  • Page 61: Towing

    Safety 2.3 Precautions for operation 2.3.5 Towing When towing Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see "Towing the machine (3-162)". Always be sure to check carefully that the capacity of the wire rope used for towing is ample for the weight of the towed machine.

  • Page 62: Precautions For Maintenance

    2.4 Precautions for maintenance Safety Precautions for maintenance Warning tag Always attach the “DO NOT OPERATE“ warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.
  • Page 63 Safety 2.4 Precautions for maintenance Maintenance with engine running Stop the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground and stop the engine.
  • Page 64 2.4 Precautions for maintenance Safety Lock the front and rear frames with safety bar (4). Free Lock GK047005 Two workers for maintenance when engine is running To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine run- ning, carry out the operation with at least two workers and do as follows.
  • Page 65 Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. GK032078 When disposing of the accumulator, the gas must be released. Please contact your KOMATSU distributor to have this work performed. 2-37 WA470-6H – VEAM946100...
  • Page 66 2.4 Precautions for maintenance Safety Personnel Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer. Attachments Appoint a leader before starting removal or installation oper- ations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall.
  • Page 67 Safety 2.4 Precautions for maintenance Precautions when using hammer When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as fol- lows. If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, there is a hazard that pieces might be scattered and cause injury.
  • Page 68 Do not remove the E.C.S.S. piping or components. If it is necessary to remove them, please ask your KOMATSU distributor to carry out the removal operation. Precautions for high-pressure fuel High pressure is generated inside the engine fuel piping when the engine is running.
  • Page 69 If any damaged hoses are found, stop operations immedi- ately and contact your KOMATSU distributor. Replace all hoses every 2 years at the latest. The shelf life of the hose should not exceed 2 years.
  • Page 70 2.4 Precautions for maintenance Safety Maintenance of air conditioner If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite. Never touch refrigerant. Compressed air When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.

  • Page 71: Precautions With Tires

    To maintain safety, always do as follows. Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special technology, so always ask your KOMATSU distributor to carry out these operations. GK032084 Inflate tyres up to the defined pressure. If the tyre pressure is too low, the tyres may heat up and burst.
  • Page 72 2.5 Precautions with tires Safety Precautions when storing tires Tires for construction equipment are extremely heavy, so they may cause serious personal injury. Basically, tyres must be stored in a protected room that can- Block not be accessed by unauthorised persons. Place the tyres on an even surface and incline them 60°...

  • Page 73: Operation

    Operation 3. Operation WARNING Please read and make sure that you understand the SAFETY section before reading this section. WA470-6H – VEAM946100...

  • Page 74: General View

    3.1 General view Operation General view 3.1.1 General view of machine GK047006 (1) Bucket (8) Turn signal lamp (2) Tilt lever (9) Head lamp (3) Front wheel (10) Lift cylinder (4) Bucket cylinder (11) Lift arm (5) Front working lamp (12) Rear working lamp (6) ROPS cab (13) Rear combination lamp...

  • Page 75: General View Of Controls And Gauges

    Operation 3.1 General view 3.1.2 General view of controls and gauges GK038016 (1) Gearshift lever stopper (13) Parking brake switch (2) Rear wiper switch (14) Cigarette lighter (3) Front wiper switch (15) Kickdown switch (4) Gearshift lever (16) Directional selector switch (5) Front switch panel (17) Lift arm control lever (6) Directional lever...
  • Page 76 3.1 General view Operation Front switch panel GK038016 (1) Monitor panel mode selector switch 1 (2) Monitor panel mode selector switch 2 (3) Front working lamp switch (4) Rear working lamp switch WA470-6H – VEAM946100...
  • Page 77 Operation 3.1 General view Right switch panel GK038017 (1) Transmission shift mode selector switch (2) Transmission cut-off switch (3) Transmission cut-off set switch (4) Directional selector switch actuation switch (5) Emergency steering switch (6) Engine power mode selector switch (7) Torque converter lock-up switch (Option) (8) Cooling fan reverse rotation switch (9) Starting switch WA470-6H –...
  • Page 78 3.1 General view Operation Machine monitor GK038018 (1) Central warning lamp (22) Joystick pilot lamp (Option) (2) Brake oil pressure caution lamp (23) Directional selector pilot lamp (3) Engine oil pressure caution lamp (24) Shift indicator (4) Fuel filter water detection caution lamp (25) Autoshift pilot lamp (5) Radiator coolant level caution lamp (26) Lock-up pilot lamp (Option)

  • Page 79: Explanation Of Components

    The indicator gauges and meters are actuated after the above system check is completed. The character display shows “KOMATSU“ for 3 seconds. If the lamps do not light up, there is probably a failure or discon- nection, so contact your KOMATSU distributor for inspection.

  • Page 80: Types Of Warning

    3.2 Explanation of components Operation Types of warning If an abnormality occurs on the machine, or if any switch or lever is operated accidently, the monitor display and buzzer give a warning to inform the operator. Following are the types of warning depending on the level of danger.

  • Page 81: Central Warning Lamp

    Operation 3.2 Explanation of components Mistaken operation This warning is given if any switch or lever is operated mistak- enly. The central warning lamp on the monitor lights up and the alarm buzzer sounds at the same time. In addition, in the following case, action code “E00“ is displayed on character display (1).

  • Page 82: Character Display Portion

    3.2 Explanation of components Operation Character display portion GK038018 1 ~ 4 (1) Service meter (2) Action code display (3) Failure code display (4) Filter, oil replacement time display Normally, the service meter is displayed on the character dis- play. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed to recommend suit-...
  • Page 83 If action code E03 is displayed, stop the machine immediately and check the failure code. For details, see "Failure code display (3-13)". Inform your KOMATSU distributor of the failure code and ask for repairs. If there is a failure on the machine, or it is necessary to change...
  • Page 84 3.2 Explanation of components Operation E03: When this code is displayed, stop the machine immedi- ately, check the failure code, and contact your KOMATSU dis- E 0 3 tributor for repairs. C H E C K R I G H T...
  • Page 85 If an action code is displayed on the character display, check the failure code according to the failure code display method given below. When contacting your KOMATSU distributor to request repairs, please inform your distributor of the failure code. Method of displaying failure code 1.
  • Page 86 3.2 Explanation of components Operation 4. Filter, oil replacement time display 1 3 : T M F I L T After completion of the system check and when the starting switch is in the ON position, if any filter or oil item is approaching 1 0 H the replacement time, this display shows the item for approx.
  • Page 87 Operation 3.2 Explanation of components REMARK See the section below for details of the procedure for replacing the filter and oil. Engine oil "Change oil in engine oil pan, replace engine oil filter car- tridge (4-68)" Engine oil filter "Change oil in engine oil pan, replace engine oil filter car- tridge (4-68)"...

  • Page 88: Emergency Stop Item

    3.2 Explanation of components Operation Emergency stop item CAUTION If these lamps light up and the buzzer sounds, stop operations immediately and carry out inspection and maintenance of the applicable location. If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the lamp for the loca- tion of the abnormality and the central warning lamp will light up.
  • Page 89 Operation 3.2 Explanation of components 1. Brake oil pressure caution lamp This lamp (1) lights up when the brake oil pressure goes below the specified value. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), the brake circuit is not actuated while the engine is stopped, so the brake oil pressure caution lamp and central warning lamp do not light up and the alarm buzzer does not sound.
  • Page 90 3.2 Explanation of components Operation 3. Battery charge circuit caution lamp This lamp (3) lights up when the engine is running to warn the operator that an abnormality has occurrred in the charging cir- cuit. During checks before starting (starting switch at the ON position, engine stopped) the lamps are lighted up, and when the engine is started, the lamps go out.

  • Page 91: Caution Items

    Operation 3.2 Explanation of components Caution items CAUTION If these lamps light up, stop operations quickly and carry out the following action. GK038018 (1) Axle oil temperature caution lamp (2) Torque converter oil temperature caution lamp (3) Engine coolant temperature caution lamp (4) Hydraulic oil temperature caution lamp (5) Fuel level caution lamp 3-19...
  • Page 92 3.2 Explanation of components Operation 1. Axle oil temperature caution lamp This lamp (1) lights up to warn the operator that the axle oil tem- perature has risen. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up.
  • Page 93 Operation 3.2 Explanation of components 3. Engine coolant temperature caution lamp This lamp (3) lights up to warn the operator that the engine cool- ant water temperature has risen. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up.

  • Page 94: Inspection And Maintenance Item

    3.2 Explanation of components Operation Inspection and maintenance item CAUTION If these lamps light up, stop operations quickly and carry out the following action. GK038018 (1) Radiator coolant level caution lamp (2) Engine oil level caution lamp (3) Battery electrolyte level caution lamp (4) Maintenance caution lamp (5) Air cleaner clogging caution lamp (*) (6) Transmission oil filter clogging caution lamp...
  • Page 95 Operation 3.2 Explanation of components 1. Radiator coolant level caution lamp This lamp (1) lights up to warn the operator that the coolant level in the radiator has gone down. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor lights up if the coolant level in the radiator is low.
  • Page 96 3.2 Explanation of components Operation 4. Maintenance caution lamp CAUTION If the caution lamp lights up, repair the problem as soon as pos- sible. If this is left as it is, it will lead to failure. When the time for filter and oil change is reached, this lamp (4) flashes or lights up for approx.
  • Page 97 Operation 3.2 Explanation of components 6. Transmission oil filter clogging caution lamp This lamp (6) is not used. GK032105 7. Fuel filter water detection caution lamp This lamp (7) is not used. GK050032 3-25 WA470-6H – VEAM946100...

  • Page 98: Pilot Display Portion

    3.2 Explanation of components Operation Pilot display portion When the starting switch is ON, the pilot display lights up when the display items are functioning. GK038018 (1) Parking brake pilot lamp (2) Cooling fan reverse rotation pilot lamp (3) Emergency steering pilot lamp (4) Output mode pilot lamp (power mode) (5) Preheating pilot lamp (6) Semi auto digging pilot lamp (Option)
  • Page 99 Operation 3.2 Explanation of components 1. Parking brake pilot lamp This lamp (1) lights up when the parking brake is applied. When the parking brake switch is turned ON, the parking brake pilot lamp lights up. GK032107 2. Cooling fan reverse rotation pilot lamp This lamp (2) lights up when the direction of rotation of the cool- ing fan is reversed.
  • Page 100 3.2 Explanation of components Operation 4. Output mode pilot lamp (power mode) This lamp (4) lights up when the power mode is selected. When the engine power mode selector switch is used to select power mode, the pilot lamp lights up. For details, see "Power mode selector switch (3-42)".
  • Page 101 Operation 3.2 Explanation of components 8. Joystick pilot lamp (Option) This lamp (8) is not used. GK050034 9. Directional selector pilot lamp This lamp (9) lights up when the directional selector switch actu- ation switch on the right switch panel is turned ON. It shows that it is possible to switch the direction of travel between FORWARD and REVERSE with the directional switch at the side of the lift arm control lever.
  • Page 102 3.2 Explanation of components Operation 12. Auto-shift pilot lamp This lamp (12) lights up when the auto-shift function is selected. When the transmission auto shift/manual shift selector switch is set to auto shift, the pilot lamp lights up. Use the transmission shift mode selector switch to select the shift mode.
  • Page 103 Operation 3.2 Explanation of components 16. Turn signal pilot lamp When the turn signal lamp flashes, this lamp (16) also flashes. REMARK If there is a disconnection in the turn signal lamp, the flashing interval becomes shorter. GK032111 17. Head lamp high beam pilot lamp This lamp (17) lights up when the head lamp is at high beam.

  • Page 104: Meter Display Portion

    3.2 Explanation of components Operation Meter display portion GK038018 (1) Torque converter oil temperature gauge (2) Engine cooling water temperature gauge (3) Hydraulic temperature gauge (4) Fuel gauge (5) Speedometer (6) Meter display pilot lamp 3-32 WA470-6H – VEAM946100...
  • Page 105 Operation 3.2 Explanation of components 1. Torque converter oil temperature gauge This meter (1) indicates the torque converter oil temperature. During normal operations, the indicator should be in the white range (A). If it enters red range (B) during operations, caution lamp (C) inside the torque converter oil temperature gauge will light up.
  • Page 106 It is also possible to display the engine speed by switching meter (5). If you wish to switch between the speedometer and tachometer, please contact your KOMATSU distributor to have it switched. GK032116 6. Meter display pilot lamp This lamp (6) displays the unit for the travel speed or engine tachometer.

  • Page 107: Other Functions Of Machine Monitor

    Operation 3.2 Explanation of components Other functions of machine monitor The machine monitor also has the following functions. Odometer, filter/oil replacement time reset, telephone number input, language selection, monitor brightness adjustment. Method of displaying odometer Use this when checking the total distance that the machine has traveled.
  • Page 108 3.2 Explanation of components Operation Reset method for filter, oil replacement time The filter and oil replacement time is displayed on the character display, so if the filter and oil have been replaced, reset the filter and oil change time. 1.
  • Page 109 Operation 3.2 Explanation of components Input method for telephone number It is possible to display the telephone number on the right side of “CALL“ displayed on the character display when action code “E03“ is generated. 1. Press the (&) of monitor panel mode selector switch 1, and display the odometer.
  • Page 110 3.2 Explanation of components Operation Method for selecting language Use this when switching the language displayed on the charac- ter display. The following explanation is for when English is set as the lan- guage for the character display. 1. Press the (&) of monitor panel mode selector switch 1, and display the odometer.
  • Page 111 Operation 3.2 Explanation of components Method of adjusting monitor brightness Do as follows to adjust the brightness of the monitor. 1. Press the (&) of monitor panel mode selector switch 1, and display the odometer. O D O < > 1 2 3 4 .

  • Page 112: Switches

    3.2 Explanation of components Operation 3.2.2 Switches GK038020 3-40 WA470-6H – VEAM946100...
  • Page 113 Operation 3.2 Explanation of components (1) Starting switch (2) Power mode selector switch (3) Transmission shift mode selector switch (4) Transmission cut-off switch (5) Transmission cut-off set switch (6) Lamp switch (6) Turn signal lever (6) Dimmer switch (7) Horn button (8) Hazard lamp switch (9) Parking brake switch (10) Front working lamp switch...
  • Page 114 3.2 Explanation of components Operation 1. Starting switch This switch (1) is used to start or stop the engine. (A): OFF position It is possible to insert and remove the starting switch key, all the electric system switches are turned off, and the engine stops. In addition, the parking brake is automatically applied.
  • Page 115 Operation 3.2 Explanation of components 3. Transmission shift mode selector switch This switch (3) is used to change the shift point when the AUTO SHIFT/MANUAL selector switch has been switched to auto shift. At each of the L, H positions, the system switches to auto shift and the auto shift pilot lamp on the machine monitor lights up.
  • Page 116 3.2 Explanation of components Operation 5. Transmission cut-off set switch CAUTION Apply the parking brake before adjusting the transmission cut-off position. Turn this switch (5) ON to adjust the brake pedal position where the transmission is automatically shifted to Neutral. GK038025 Position (a): ON Cut-off position can be adjusted...
  • Page 117 Operation 3.2 Explanation of components 6. Turn signal lever This switch (6) is used to operate the turn signal lamp. Position (a): LEFT TURN (Push lever FORWARD.) Position (b): OFF Position (c): RIGHT TURN (Pull lever BACK.) REMARK GK043123 When the lever is operated, the turn signal pilot lamp also flashes.
  • Page 118 Apply the parking brake only after the machine has stopped. If the parking brake has been used as an emergency brake when traveling at high speed, contact your KOMATSU dis- tributor to have the parking brake checked for any abnormal- ity.
  • Page 119 Operation 3.2 Explanation of components 10. Front working lamp switch WARNING Always turn the working lamp off before traveling on public roads. When turning the front working lamp ON, operate the lamp switch to turn the side clearance lamp ON or the head lamp ON, GK038026 then operate this switch (10).
  • Page 120 3.2 Explanation of components Operation 12. Monitor panel mode selector switch 1 This switch (12) is used to switch the function of the character display. When the switch is released, it automatically returns to its origi- nal position. The basic operation is as follows. Position (&): GK038028 Press here to select (confirm) each mode or operation...
  • Page 121 Operation 3.2 Explanation of components 14. Kickdown switch When the gearshift lever is in 2nd, if switch (14) on the head of the lift arm control lever is pressed, the transmission will shift down to 1st. Use this when you need to increase the drawbar pull in digging operations.
  • Page 122 3.2 Explanation of components Operation 15. Hold switch To fix the speed range when traveling in automatic transmission, press switch (15) at the side of the lift arm control lever knob. The transmission will be fixed in the speed range displayed on shift indicator (A) on the machine monitor and shift hold pilot lamp (B) will light up.
  • Page 123 Operation 3.2 Explanation of components 17. Rear wiper switch When lever (C) of this switch (17) is turned, the rear wiper will move. Lever C Position (a): Washer liquid is sprayed out Position (b): OFF Position (c): Wiper is operated GK032134 Position (d): Washer liquid is sprayed out, wiper is operated...
  • Page 124 3.2 Explanation of components Operation 21. E.C.S.S. switch (*) (*) E.C.S.S.: Electrically Controlled Suspension System WARNING If the machine is traveling or the work equipment is raised, the moment the E.C.S.S. switch is turned ON, the work equipment will move. If the E.C.S.S.
  • Page 125 Operation 3.2 Explanation of components 22. Emergency steering switch This switch (22) is the manual control switch for the emergency steering. Even when the engine has stopped, steering operations are made possible by pressing this switch. Position (a): ON The pilot lamp inside the switch and the emergency steering pilot lamp on the machine monitor light up and it becomes possi- GK038034 ble to operate the steering.
  • Page 126 3.2 Explanation of components Operation 23. Cooling fan auto reverse rotation switch (Option) This switch (23) is used to rotate the cooling fan in the reverse direction when cleaning the radiator. Position (a): Auto reverse rotation function ON The fan automatically rotates in reverse for 2 minutes every 2 hours.
  • Page 127 Operation 3.2 Explanation of components 24. Directional selector switch This switch (24) is used to switch the direction of travel of the machine between forward and reverse. F Position: FORWARD N Position: Neutral R Position: REVERSE Before operating this switch, check that the condition is as fol- GK043139 lows.

  • Page 128: Control Levers, Pedals

    3.2 Explanation of components Operation 3.2.3 Control levers, pedals GK038016 (1) Gearshift lever (2) Directional lever (3) Gearshift lever stopper (4) Work equipment lock lever (5) Bucket control lever (6) Lift arm control lever (7) Brake pedal (8) Accelerator pedal 3-56 WA470-6H –...
  • Page 129 Position (c): 3rd Position (d): 4th REMARK The lever length can be set to 3 levels (positions (A), (B), and (C)). For adjustment, consult your KOMATSU distributor. The lever is installed to position (B) when delivered. GK047007 Automatic shift Automatic gear shifting can be carried out in the 2nd through 4th speed range of the four forward and reverse speeds depending on the travel conditions.
  • Page 130 3.2 Explanation of components Operation The range of speeds during automatic gear shifting is deter- mined by the position of the gearshift lever as shown in the chart Gear shift lever Speed range on the right. positions 2nd <-> 3rd 2nd <->...
  • Page 131 Position N: NEUTRAL Position R: REVERSE REMARK The lever length can be set to 2 levels (positions (A), (B)). For adjustment, consult your KOMATSU distributor. The lever is installed to position (A) when delivered. GK047008 3. Gearshift lever stopper This stopper (3) prevents the gearshift lever from entering the 3rd or 4th positions when working.
  • Page 132 3.2 Explanation of components Operation 4. Work equipment lock lever WARNING Before leaving the operator's seat, set the work equipment lock lever securely to the LOCK position. If the work equip- ment lock lever is not at the LOCK position, and work equip- ment control lever is touched by mistake, it may lead to a serious accident.
  • Page 133 Operation 3.2 Explanation of components 5. Bucket control lever This lever (5) operates the bucket. Position (a): TILT When the bucket control lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position.
  • Page 134 3.2 Explanation of components Operation 7. Brake pedal WARNING When traveling downhill, always use the right brake pedal, and use the braking force of the engine together with the brake. Do not use the brake pedal excessively. If the brake is used too frequently, the brake will overheat.

  • Page 135: Steering Tilt Lock Lever

    Operation 3.2 Explanation of components 3.2.4 Steering tilt lock lever WARNING Stop the machine before adjusting the tilt of the steering wheel. If this operation (adjustment) is carried out while the machine is moving, it may lead to a serious accident or personal injury. This lever is used to unlock and lock the steering column when adjusting the position of the steering column to the front or rear or up or down.

  • Page 136: Cap With Lock

    3.2 Explanation of components Operation 3.2.5 Cap with lock Use the starting key to open and close the locks on the caps. The fuel tank filler port and the hydraulic tank filler port are equipped with locks. Shoulder GK032149 Method of opening and closing cap with lock (for the fuel tank filler port) To open the cap Match mark...

  • Page 137: Safety Bar

    Operation 3.2 Explanation of components 3.2.6 Safety bar WARNING When carrying out maintenance or transporting the machine, always set the safety bar to the LOCK position. If the machine is transported or lifted when the safety bar is not locking the frame, the machine may suddenly articulate. If the machine articulates, it may cause serious personal injury to people in the surrounding area.

  • Page 138: Towing Pin

    3.2 Explanation of components Operation 3.2.7 Towing pin 1. Insert towing pin (1) into hole (2) in the counterweight. GK038042 2. Use linch pin (3) to set so that the towing pin does not come out. Reverse this operation to remove the pin. GK038043 3.2.8 Grease pump...

  • Page 139: Cab Door

    Operation 3.2 Explanation of components 3.2.9 Cab door CAUTION Always check that the cab door is locked, both when it is open and when it is closed. Always stop the machine on level ground before opening or closing the door. Avoid opening or closing the door on a slope.

  • Page 140: Cab Window Open Lock

    3.2 Explanation of components Operation 3.2.11 Cab window open lock Cab left window open lock reset knob Use this when raising or lowering the glass in the window of the left door. Grip lock release knob (1), release the lock, then remove the glass down to the lower lock position.

  • Page 141: Backup Alarm

    Operation 3.2 Explanation of components 3. Open the right window fully and escape through the window. When returning the open lock knob to its original position, pull the window to a position where it is possible to lock it, align the open lock guide rail with the guide, then push in the open lock knob to the front.

  • Page 142: Fuse

    3.2 Explanation of components Operation 3.2.13 Fuse NOTE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burn- ing out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.

  • Page 143: Slow Blow Fuse

    Operation 3.2 Explanation of components Fuse box B Fuse Name of circuit capacity Engine control B Rear heated wire glass Air suspension seat Yellow rotating lamp (Option) Turn signal indicator Car radio, cigarette lighter, 12V power source Rear working lamp Front working lamp Spare 1 (10)

  • Page 144: Power Outlet

    3.2 Explanation of components Operation 3.2.15 Power outlet NOTE There are two power sources: 12V (Option) and 24V Check the voltage of the electrical equipment and select the appropriate power source. Mistaken use, such as using 24V as the power source for 12V equipment, will cause failure of the equipment.

  • Page 145: Air Conditioner (Standard)

    Operation 3.2 Explanation of components 3.2.16 Air conditioner (standard) By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it possible to pro- vide a pleasant working environment even on dusty jobsites. General locations and function of control panel FACE FACE...
  • Page 146 3.2 Explanation of components Operation 1. Main power switch Use the switch (1) to turn the main power of the air conditioner ON/OFF. When the switch is pressed, display monitor (A) lights up. The fan begins operation. When the switch is pressed again, the air conditioner is turned OFF and the display monitor goes out.
  • Page 147 Operation 3.2 Explanation of components 3. Air conditioner switch Use this switch (3) to actuate the cooling, heating, or dehumidi- fying functions, or to stop the air conditioner. When the main power switch is ON, if the air conditioner switch is pressed, the air conditioner is turned ON and (A) is displayed on the display monitor.

  • Page 148: Method Of Operation

    3.2 Explanation of components Operation 5. Fresh/Recirc selector switch Use this switch (5) to switch between recirculation of the air inside the cab and intake of fresh air from outside. When this switch is pressed, recirculation of inside air is selected and (A) lights up on the display monitor.
  • Page 149 Operation 3.2 Explanation of components Heating operation 1. Press main power switch (1) of the air conditioner to turn the power ON. 2. Press fan switch (2) and set the air flow to “Hi“. 3. Press temperature control switch (3) and set the display monitor to HOT (A).

  • Page 150: Precautions When Using

    When adding refrigerant or carrying out other maintenance, spe- cial tools and instruments are needed, so ask your KOMATSU distributor to carry out inspection and repair. 3-78 WA470-6H – VEAM946100...

  • Page 151: Cool Box

    Operation 3.2 Explanation of components Cool box When the cooling is being used, this can be used for keeping drinks and other things cool. When the heating is being used, it can be used to keep things warm. When using the box, open the vent grill. When not using the box, close the grill.

  • Page 152: Air Conditioner (Automatic)

    3.2 Explanation of components Operation 3.2.17 Air conditioner (automatic) (Option) By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it possible to pro- vide a pleasant working environment even on dusty jobsites. General locations and function of control panel FACE FACE...
  • Page 153 Operation 3.2 Explanation of components 1. Main power switch Use the switch (1) to turn the main power of the air conditioner ON/OFF. When the switch is pressed, display monitor (A) lights up. The fan begins operation. When the switch is pressed again, the air conditioner is turned OFF and the display monitor goes out.
  • Page 154 3.2 Explanation of components Operation 3. Air conditioner switch Use this switch (3) to actuate the cooling, heating, or dehumidi- fying functions, or to stop the air conditioner. When the main power switch is ON, if the air conditioner switch is pressed, the air conditioner is turned ON and (A) is displayed on the display monitor.
  • Page 155 Operation 3.2 Explanation of components 6. Fresh/Recirc selector switch Use this switch (6) to switch between recirculation of the air inside the cab and intake of fresh air from outside. When this switch is pressed, recirculation of inside air is selected and (A) lights up on the display monitor.

  • Page 156: Method Of Operation

    3.2 Explanation of components Operation Method of operation Cooling operation 1. Press main power switch (1) of the air conditioner to turn the power ON. 2. Press fan switch (2) and set the air flow to “Hi“. 3. Press temperature control switch (3) to set to the desired temperature.
  • Page 157 Operation 3.2 Explanation of components Drying-heating and demisting operation 1. Press main power switch (1) of the air conditioner to turn the power ON. 2. Press fan switch (2) and set the air flow to the desired set- ting. 3. Press temperature control switch (3) to set to the desired temperature.

  • Page 158: Precautions When Using

    When adding refrigerant or carrying out other maintenance, spe- cial tools and instruments are needed, so ask your KOMATSU distributor to carry out inspection and repair. 3-86 WA470-6H – VEAM946100...

  • Page 159: Handling Cab Wiper

    Operation 3.2 Explanation of components 3.2.18 Handling cab wiper Preventing damage to wiper arm bracket NOTE When angling the wiper arm (1) to the front, check that the wiper blade is hanging free. When angling the wiper arm (1) to the front, such as when wip- ing the glass clean, if the wiper arm (1) is angled with the wiper blade (2) locked to the arm (the bottom of the blade is caught on the arm), abnormal force is brought to bear on the mounting...
  • Page 160 Leakage of fuel or oil will cause the machine to catch fire. Check carefully, and be sure to repair any abnor- malities, or please contact your KOMATSU distributor. Always repair any damage to the handrails and steps, and tighten any loose bolts.
  • Page 161 Operation 3.3 Operation 4. Check for oil leakage from transmission case, axle, hydraulic tank, hoses, joints. Check that there is no oil leakage. If any abnormality is found, repair the leakage. 5. Check for oil leakage from brake line. Check that there is no oil leakage. If any abnormality is found, repair the leakage.
  • Page 162 3.3 Operation Operation 11. Check for damage to seat belt and mounting clamps. Check that there are no loose bolts on the equipment mount- ing the seat belt to the machine, and tighten if necessary. If the belt is damaged or fluff is starting to form, or if there is any damage or deformation of the seat belt holders, replace the seat belt.
  • Page 163 2 seconds and the alarm buzzer sounds for approx. 2 sec. If the lamps do not light up, there is probably a failure or dis- connection. Contact your KOMATSU distributor for inspec- tion. GK038005 3-91...
  • Page 164 3.3 Operation Operation Check coolant level, add coolant WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
  • Page 165 Operation 3.3 Operation Check oil level in engine oil pan, add oil WARNING Engine parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. 1.
  • Page 166 3.3 Operation Operation Check water separator WARNING Each part of the engine is still highly heated immediately after the engine is stopped. Do not attempt to drain cooling water or remove the filter element cup. High pressure is generated inside the engine fuel piping, while the engine is running.
  • Page 167 Operation 3.3 Operation REMARK If plug (2) is stiff, coat O-ring (5) of plug (2) with grease. 1. Set a fuel container under drain hose (4). 2. Loosen plug (2), then drain all the sediment together with the fuel from drain hose (4). 3.
  • Page 168 3.3 Operation Operation Check air cleaner element WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
  • Page 169 Operation 3.3 Operation Check fuel level, add fuel WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames near fuel because it is highly flammable and dangerous. NOTE If the engine has stopped because it has run out of fuel, it is nec- essary to bleed all the air from the circuit before starting again.
  • Page 170 CAUTION If fuses are frequently blown or if there are traces of short-circuit- ing on the electrical wiring, promptly ask your KOMATSU distrib- utor to locate the cause and make the repair. Keep the top surface of the battery clean and check the breather hole in the battery cap.
  • Page 171 Operation 3.3 Operation Adjustment Seat adjustment WARNING When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK position to prevent any accidental contact to the control levers. Always adjust the operator's seat before starting each oper- ation or when the operators change shift.
  • Page 172 3.3 Operation Operation Safety belt WARNING Danger of injury! A damaged safety belt, a safety belt that has been stretched in an accident, or a safety belt the belt fixings or fastening screws of which have not been mounted correctly will not protect you sufficiently in case of accident! Replace the safety belt, if it is damaged, or if the machine has been involved in an accident.
  • Page 173 Operation 3.3 Operation Adjust lever stand WARNING When adjusting the lever stand, check that the work equip- ment lock lever is securely at the LOCK position. If it is not at the LOCK position, and the work equipment con- trol levers are touched by accident when adjusting the lever stand, the work equipment may suddenly move and cause serious personal injury.
  • Page 174 GK047017 Tightening torque Mirrors A, B: 2.0 to 2.5 Nm Mirrors C: 8.8 to 9.8 Nm If the tightening torque cannot be controlled, ask your KOMATSU distributor for tightening the bolts. 3-102 WA470-6H – VEAM946100...
  • Page 175 Operation 3.3 Operation Operations and checks before starting engine WARNING Before starting the engine, check that the work equipment lock lever (3) is securely at the LOCK position. If the work equipment control lever is touched by accident when starting the engine, the work equipment may move unexpectedly and cause serious damage or personal injury.
  • Page 176 2 seconds, and the alarm buzzer sounds for approx. 2 sec. If any monitor does not light up, there is probably a failure or disconnection, so contact your KOMATSU distributor for GK038021 inspection. In addition, after all the monitors, gauges, and central warn- ing lamp light up, a self check is carried out to check that the emergency steering function works properly.
  • Page 177 Operation 3.3 Operation 3.3.2 Starting engine Normal starting WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire.
  • Page 178 3.3 Operation Operation The time that the preheating pilot lamp (2) stays lighted up depends on the ambient temperature as shown in the table Ambient Lighting time on the right. temperature 0 seconds to -1°C to -15°C 30 seconds -15°C or less 30 seconds 2.
  • Page 179 Operation 3.3 Operation Starting in cold weather WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. Check that there are no persons or obstacles in the sur- rounding area, then sound the horn and start the engine.
  • Page 180 3.3 Operation Operation (X): Preheating time (sec.) (Y): Start-up temperature (°C) GK047018 2. When preheating pilot lamp (2) goes out, turn the key in starting switch (1) to the START position (C). Keep the key in starting switch (1) at the START position (C) to keep the starting motor running until the engine starts.
  • Page 181 Operation 3.3 Operation Automatic warming-up operation After starting the engine, if the engine water temperature is below 20°C, the automatic warming-up operation (engine speed: 1020 rpm) is carried out, and is cancelled when the engine water temperature goes above 30°C. (Engine speed: 800 - 850 rpm) (X) :Engine speed (rpm) (Y) :Water temparture (°C) GK047019...
  • Page 182 Breaking-in the machine CAUTION Your KOMATSU machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the per- formance and shorten the machine life.
  • Page 183 Operation 3.3 Operation Normal operation After starting the engine, do not immediately start operations. First, carry out the following operations and checks. NOTE Do not suddenly accelerate the engine before the warming-up operation is completed. Do not run the engine at low idling or high idling continuously for more than 20 minutes.
  • Page 184 Select the oil from the table of recommended oils below accord- ing to the ambient temperature. If KOMATSU EO10W30-DH is used in the cold season, replace it with KOMATSU EO15W40-DH oil when the cold season fin- ishes.
  • Page 185 Operation 3.3 Operation 3.3.4 Stopping engine NOTE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine except for an emergency. In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop GK038080 1.
  • Page 186 3.3 Operation Operation 3.3.6 Moving the machine (directional, speed), stopping the machine WARNING Always remove the frame lock bar for travel operations. If it is not removed, the steering wheel cannot be used for steer- ing, and this may lead to serious damage or injury. When moving the machine, check that the area around the machine is safe, then sound the horn before starting.
  • Page 187 Operation 3.3 Operation 2. Check that the bucket control lever (2) and lift arm control lever (3) is at the HOLD position, then set the work equip- ment lock lever (4) to the FREE position. Free Lock GK038007 3. Operate lift arm control lever (3) to set the work equipment to the travel posture shown in the diagram on the right.
  • Page 188 Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does not sound, please GK043144 contact your KOMATSU distributor for repairs. 7. Release right brake pedal (5), then depress accelerator pedal (9) to move the machine.
  • Page 189 Operation 3.3 Operation Changing gear speed WARNING When traveling at high speed, do not shift gear suddenly. Use the brake to reduce the travel speed before shifting gear. Do not switch between FORWARD and REVERSE when traveling at high speed. When switching between FORWARD and REVERSE, depress the brake to reduce the travel speed sufficiently, then change the direction of travel.
  • Page 190 Check that the backup alarm sounds when the directional lever GK043144 is set to REVERSE. If the backup alarm does not sound, please contact your KOMATSU distributor for repairs. REMARK If the directional lever is operated slowly or is stopped midway between the forward and reverse directions, “E01 MAINTE-...
  • Page 191 Operation 3.3 Operation When using auto-shift If an attempt is made to switch the direction between forward and reverse when the auto-shift is ON, normally, the gearshift range will switch F3 -> R2, F4 -> R2, or R3 -> F2, R4 -> F2 to make it possible to move the machine off quickly.
  • Page 192 3.3 Operation Operation Using switch to change between forward and reverse WARNING If the directional switch actuation switch is ON and the directional lever is operated to the FORWARD position (F) or REVERSE posi- tion (R), the direction of travel will change to FORWARD or REVERSE, regardless of the position of the directional switch at the side of the control levers on the machine.
  • Page 193 Operation 3.3 Operation If the switch or the lever is in one of the following conditions, set it to the correct position. When directional lever is not at Neutral position (N) If the directional lever is not at the Neutral position (N), the pilot lamp flashes, and at the same time, the central warning lamp lights up and the alarm buzzer sounds.
  • Page 194 3.3 Operation Operation Stopping the machine WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Even if the parking brake lever is pulled and set to the LOCK position, there is a danger of the machine moving until the parking brake pilot lamp lights up, so keep the brake pedal depressed.
  • Page 195 Operation 3.3 Operation Transmission cut-off function When the transmission cut-off switch is turned ON, the pilot lamp lights up and the following transmission cut-off function is actuated. Position (a): OFF Position (b): ON When the brake pedal is depressed, the brakes are actuated and the transmission is returned to Neutral when the brake pedal is depressed to the set position.
  • Page 196 3.3 Operation Operation Adjusting transmission cut-off position WARNING Apply the parking brake before adjusting the transmission cut-off position. Adjust the amount that the brake pedal is depressed. 1. Start the engine with starting switch (1), then set parking brake switch (2) to the ON position. 2.
  • Page 197 Check that there is a play of 50 to 100 mm in the steering wheel. Check also that the steering works properly. If any abnormality is found, please contact your KOMATSU distributor for inspection. When the emergency steering system detects that the oil pres- sure in the steering circuit has been restored, the actuation of the emergency steering system is stopped.
  • Page 198 3.3 Operation Operation Emergency steering CAUTION Never actuate the emergency steering except during emer- gencies or when checking the function. The emergency steering can be used continuously for a maximum of 60 seconds. Operating it continuously for more than 60 seconds may damage the system. When using the emergency steering, travel at a speed of less than 5 km/h.
  • Page 199 Operation 3.3 Operation Locate the cause and do not operate the machine until it has been repaired. REMARK If any function of the oil pressure system is used when the engine is running at low speed, steering oil pressure caution lamp (red) (3) may light up for a moment, but if the lamp goes out again soon, there is no problem.
  • Page 200 3.3 Operation Operation 3.3.8 Operation of work equipment WARNING When standing up from the operator's seat, always set the work equipment lock lever securely to the LOCK position. If the work equipment lock lever is not locked, and work equip- ment control lever (A) is touched by mistake, this may lead to serious personal injury.
  • Page 201 Operation 3.3 Operation Lift arm operation Set the work equipment lock lever to the FREE position before operating the control lever. NOTE Do not use the FLOAT position when lowering the bucket. Use the FLOAT position when leveling, see "Leveling operation (3-134)". Position (a): RAISE When the lift arm control lever is pulled further from the RAISE position, the lever is stopped in this position until the lift arm...
  • Page 202 3.3 Operation Operation 3.3.9 Work possible using wheel loader In addition to the following, it is possible to further increase the range of applications by using various attachments. Digging operations WARNING Never carry out digging or scooping operations with the machine articulated.
  • Page 203 Operation 3.3 Operation REMARK To reduce fuel consumption, depress the accelerator pedal the minimum possible amount. If it is depressed fully, the fuel con- sumption will increase, but there will be no increase in the amount loaded. 3. When the material is in a stockpile, keep the cutting edge of the bucket horizontal;...
  • Page 204 3.3 Operation Operation 5. Check that there is enough material loaded into the bucket, then operate the bucket control lever to tilt the bucket and load the bucket fully. REMARK If the bucket edge is moved up and down while pushing in the bucket and digging, the front tires will come off the ground and this will cause the tires to slip.
  • Page 205 Operation 3.3 Operation Digging and loading on level ground When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the machine forward. Always be careful not to load the bucket on one side and cause an unbalanced load.
  • Page 206 3.3 Operation Operation Leveling operation NOTE Always operate the machine in reverse when carrying out leveling operations. If it is necessary to carry out leveling operations when travel- ing forward, do not set the bucket dumping angle to more than 20 degrees. Turn the E.C.S.S.
  • Page 207 Operation 3.3 Operation Loading operations Select the method of operation which will give the minimum amount of turning and travel in order to provide the most efficient method for the jobsite. WARNING Always keep the jobsite flat, and do not operate the steering wheel suddenly or apply the brakes suddenly when the lift arm is raised with a loaded bucket.
  • Page 208 3.3 Operation Operation V-shape loading Position the dump truck so that the direction of approach of the wheel loader is approx. 60 degrees from the direction of approach to the stockpile. After loading the bucket, drive the wheel loader in reverse, then turn it to face the dump truck and travel forward to load the dump truck.
  • Page 209 NOTE If the parking brake has been used as an emergency brake, con- tact your KOMATSU distributor to have the parking brake checked for any abnormality. Precautions when driving up or down slopes...
  • Page 210 The most suitable tire pressure, travel speed, or tire type dif- fer according to the condition of the travel surface. Contact your KOMATSU distributor or tire dealer for information. When traveling on a paved road surface using normal tires (26.5-R25), the guideline for the appropriate tire inflation pressure and travel speed is as follows.
  • Page 211 Downhill distance limit (km/h) (continuous) (km) 22 - 24 (unloaded) 28.5 - 30.5 (loaded) If the braking capacity limit is exceeded, a forced cooling system for the brakes is needed, so please consult your KOMATSU dis- tributor. 3-139 WA470-6H – VEAM946100...
  • Page 212 3.3 Operation Operation 3.3.11 Adjusting work equipment posture WARNING Stop the machine on flat ground and put blocks in front and behind the wheels. Set the parking brake switch to the ON position (A) to apply the parking brake. Secure the front and rear frames with the safety bar. Always attach the warning tag to the work equipment control lever.
  • Page 213 Operation 3.3 Operation Adjusting bucket positioner 1. Lower the bucket to the ground, set to the desired digging angle, return the bucket control lever at HOLD, then set the safety lever to the LOCK position and stop the engine. 2. Loosen 2 bolts (1), adjust the position of mounting bracket (4) of the proximity switch so that the rear tip of bar (2) is in line with the center of the sensing surface of proximity switch (3), then tighten bolts to hold the bracket in position.
  • Page 214 3.3 Operation Operation 3.3.12 Parking machine WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.
  • Page 215 Operation 3.3 Operation 3. Set parking brake switch (4) to the ON position (A) to apply the parking brake. NOTE When the parking brake is applied, the transmission is automati- cally returned to neutral. GK038008 4. Operate lift arm control lever (5) to lower the bucket to the ground.
  • Page 216 3.3 Operation Operation 3.3.13 Checks after completion of operation Before stopping engine Check the engine water temperature, engine oil pressure, torque converter oil temperature, and fuel level with the machine moni- tor. If the engine has overheated, do not stop it suddenly. Run the engine at a midrange speed to allow the engine to cool down before stopping it.
  • Page 217 Operation 3.3 Operation 3.3.14 Locking Always lock the following parts. (1) Fuel tank filler cap (2) Engine side cover (2 places) (3) Cab door (4) Rear grille (5) Air conditioner fresh air filter (6) Transmission filler cover GK047016 REMARK The starting switch key is used also for locks (1) to (6). GK047023 GK038091 GK038092...
  • Page 218 Side wall Bead Do not install a tire protector (mesh chain) to the rear tires. GK032223 Please contact your KOMATSU distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. Tire pressure Measure the tire pressure before starting operations, when the tires are cool.
  • Page 219 Operation 3.3 Operation Clearing fallen stones and rocks from the operating area and maintaining the surface will extend the tire life and give improved economy. For operations on normal road surfaces, rock digging opera- tions: High end of range in air pressure chart Stockpile operations on soft ground: Average pressure in air pressure chart Operations on sand (operations not using much digging...
  • Page 220 If this is not done, the tires will be damaged, so contact your KOMATSU dis- tributor or tire dealer when selecting tires.
  • Page 221 Operation 3.4 Transportation Transportation When transporting the machine, observe all related laws and regulations, and be careful to assure safety. 3.4.1 Transportation procedure As a basic rule, always transport the machine on a trailer. When selecting the trailer, see the weights and dimensions given in Section "Technical data (5-2)".
  • Page 222 3.4 Transportation Operation Loading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the brakes on the trailer securely and insert blocks under the tires to ensure that the trailer does not move. Then fix the ramps in line with the centers of the trailer and the machine.
  • Page 223 Operation 3.4 Transportation 5. Lock front frame and rear frame with safety bar. Free Lock GK047005 6. Put blocks in front and behind the wheels, and secure the machine with chains or wire rope to prevent the machine from moving during transportation. In particular, attach the machine securely to prevent it from slipping sideways.
  • Page 224 3.4 Transportation Operation Unloading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the brakes on the trailer securely and insert blocks under the tires to ensure that the trailer does not move. Then fix the ramps in line with the centers of the trailer and the machine.
  • Page 225 The lifting procedure applies to machines with standard specifi- cations. The method of lifting differs according to the attachments and options actually installed. In such cases, please contact your KOMATSU distributor for information. For details of the weight, see "Weight table (3-154)". 3-153 WA470-6H – VEAM946100...
  • Page 226 3.4 Transportation Operation Location of lifting position mark GK038094 Lifting hooks (A) are located at 4 places on the machine as shown in the diagram on the right. Use only these 4 places when lifting; do not use any other places.
  • Page 227 When the machine is raised, check that there is no oil leakage from the hydraulic circuits. When carrying out the lifting operation, please contact your KOMATSU distributor. Lifting work can be carried out only for machines with lifting marks. Before starting the lifting operation, stop the machine in a horizontal place and do as follows.
  • Page 228 Avoid using any leak-preventing agent, regardless if it is sold separately or in antifreeze. Do not mix one antifreeze with a different brand. When using KOMATSU Supercoolant (AF-NAC), there is no need to use a corrosion resistor. For details, see "Clean inside of cooling system (4-35)".
  • Page 229 Operation 3.5 Cold weather operation Battery WARNING The battery generates flammable gas, so do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and con- sult a doctor.
  • Page 230 3.5 Cold weather operation Operation 3.5.2 Precautions after completion of work To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions. Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rod clean to prevent damage to the seal caused by mud or dirt on the rod surface getting inside the seal together with drops of water.
  • Page 231 Operation 3.5 Cold weather operation 3.5.4 Warming-up operation for steering hydraulic circuit in cold weather WARNING If the steering wheel is operated and stopped while the oil tem- perature is low, there may be a time lag before the machine stops turning.
  • Page 232 3.6 Long-term storage Operation Long-term storage 3.6.1 Before storage When putting the machine in storage for a long time, do as fol- lows. Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select level ground and cover the machine with a sheet.
  • Page 233 NOTE If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your KOMATSU distributor. When using the machine after long-term storage, do as follows before using it. Wipe off the grease from the hydraulic cylinder rods.
  • Page 234 3.7 Troubleshooting Operation Troubleshooting 3.7.1 When machine runs out of fuel WARNING When starting the engine again, check carefully that the area around the engine is safe before cranking the engine. When starting the engine after running out of fuel, fill with fuel and bleed the air from the fuel system before starting.
  • Page 235 The machine must not be towed for long distances. For details of the procedure for towing a machine when it has broken down, please contact your KOMATSU distribu- tor. This machine must not be towed except in emergencies. When towing the machine, take the following precautions.
  • Page 236 3.7 Troubleshooting Operation When towing a machine downhill, use a larger machine for towing to provide ample rimpull and braking power, or con- nect another machine to the rear of the machine being towed. This way it is possible to prevent the machine from losing control and turning over.
  • Page 237 Operation 3.7 Troubleshooting When engine can be used If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the machine out of mud or to move it for a short distance to the edge of the road.
  • Page 238 3.7 Troubleshooting Operation Releasing parking brake WARNING When releasing the parking brake, stop the machine on level ground and check that the surrounding area is safe. If it is necessary to release the brake on a slope in an emergency, block the tires before starting the operation.
  • Page 239 Operation 3.7 Troubleshooting 3. Turn starting switch to the ON position (B). GK038021 4. Move the parking brake switch to the ON (a) position (actu- ated), then move it to the OFF (b) position (released). The parking brake is released. GK038008 5.
  • Page 240 The normal gear shifting operation is carried out by electric sig- nals. If there should be a failure in the electrical system and the machine does not move, please contact your KOMATSU distrib- utor to have the machine moved. NOTE Always request your KOMATSU distributor to carry out the emergency travel operation.
  • Page 241 Operation 3.7 Troubleshooting 3.7.3 If battery is discharged WARNING When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. When removing, disconnect the cable from the ground (-) terminal first. The battery generates hydrogen gas, so there is a hazard of explosion.
  • Page 242 3.7 Troubleshooting Operation Removal and installation of battery 1. Before removing battery, remove the ground cable (normally connected to the negetive (-) terminal). If any tool touches between the positive terminal and the chassis, there is dan- ger of sparks being generated. Loosen the nuts of terminal and remove the wires from the battery.
  • Page 243 Operation 3.7 Troubleshooting Starting engine with booster cable When starting the engine with a booster cable, do as follows: Precautions when connecting and disconnecting booster cable WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, always wear safety glasses and rubber gloves.
  • Page 244 3.7 Troubleshooting Operation Connecting the booster cable Keep the starting switch of the normal machine and problem machine at the OFF position. Connect the booster cable as follows, in the order of the num- bers marked in the diagram. Battery of the Battery of the 1.
  • Page 245 Operation 3.7 Troubleshooting 3.7.4 Other trouble Electrical system ): Always contact your KOMATSU distributor when deal- ing with these items. In cases of abnormalities or causes which are not listed below, please contact your KOMATSU distributor for repairs. Problem Main causes...
  • Page 246 3.7 Troubleshooting Operation Chassis ): Always contact your KOMATSU distributor when deal- ing with these items. In cases of abnormalities or causes which are not listed below, please contact your KOMATSU distributor for repairs. Problem Main causes Remedy Transmission Release parking brake...
  • Page 247 Operation 3.7 Troubleshooting Problem Main causes Remedy Parking brake Linkage is loose Adjust Poor braking effect Disc is worn (Replace disc) Add oil to specified level. Lack of oil in transmission case Brake drags or remains applied See WHEN REQUIRED Screen is clogged (Disassemble, clean) Steering...
  • Page 248 3.7 Troubleshooting Operation Engine ): Always contact your KOMATSU distributor when deal- ing with these items. In cases of abnormalities or causes which are not listed below, please contact your KOMATSU distributor for repairs. Problem Main causes Remedy Add oil to specified level.
  • Page 249 Operation 3.7 Troubleshooting Problem Main causes Remedy Clean or replace. Clogged air cleaner element See WHEN REQUIRED Exhaust gas occasionally turns Defective nozzle (Replace nozzle) black Defective compression (See defective compression Defective turbocharger above) Clean or replace turbocharger Combustion noise occasionally Defective nozzle (Replace nozzle) makes breathing sound...
  • Page 250 3.7 Troubleshooting Operation 3-178 WA470-6H – VEAM946100...
  • Page 251 Maintenance 4. Maintenance WARNING Please read and make sure that you understand the SAFETY section before reading this section. WA470-6H – VEAM946100...
  • Page 252 Check the service meter reading every day to see if the time has come for any necessary maintenance to be carried out. KOMATSU genuine replacement parts: Use KOMATSU genuine parts specified in the Parts Book as replacement parts. KOMATSU genuine oils: Use KOMATSU genuine oils and grease.
  • Page 253 4.1 Guides to maintenance Maintenance Welding instructions: Cut off power. Wait for approx. one minute after turning off the engine starting switch key, and then disconnect the neg- ative (-) terminal of the battery. Do not apply more than 200 V continuously. Connect grounding cable within 1 m from the area to be welded.
  • Page 254 4.1 Guides to maintenance Maintenance Avoid mixing oil: If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade of oil. Never mix different brands or grades of oil. Locking inspection covers: Lock inspection cover in position securely with the lock bar.
  • Page 255 4.1 Guides to maintenance Maintenance Checks after inspection and maintenance: If you forget carrying out the checks after inspection and mainte- nance, unexpected problems may occur, and this may lead to serious injury or property damage. Always do as follows. Checks after operation (with engine stopped) Have any inspection and maintenance points been for- "...
  • Page 256 Engine oil EO15W40DH (KOMATSU genuine parts) Transmission case Power train oil TO30 (KOMATSU genuine parts) Hydraulic system Power train oil TO10 (KOMATSU genuine parts) Axle Axle oil AXO80 (KOMATSU genuine parts) Radiator Supercoolant AF-NAC (Density: 30% or above) (KOMATSU genuine parts) WA470-6H – VEAM946100...
  • Page 257 4.2 Outlines of service Maintenance Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) 4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pres- sure), and deteriorates with use.
  • Page 258 4.2 Outlines of service Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) Maintenance Fuel The fuel pump is a precision instrument, and if fuel contain- ing water or dirt is used, it cannot work properly.
  • Page 259 4.2 Outlines of service Maintenance Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) Coolant and water for dilution The coolant has the important function of preventing corro- sion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
  • Page 260 4.2 Outlines of service Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) Maintenance Grease Grease is used to prevent twisting and noise at the joints. This construction equipment is used under heavy-duty con- ditions. Always use the recommended grease and follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
  • Page 261 4.2 Outlines of service Maintenance Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) KOWA analysis items Analysis of metal wear particles This uses an ICP (Inductively Coupled Plasma) analyzer to measure the density of metal wear particles in the oil.
  • Page 262 4.2 Outlines of service Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) Maintenance Storing oil and fuel Keep indoors to prevent any water, dirt, or other impurities from getting in. When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at the side to prevent moisture from being sucked in.
  • Page 263 Never install any electric components other than those spec- ified by KOMATSU. External electro-magnetic interference may cause malfunc- tion of the control system controller, so before installing a radio receiver or other wireless equipment, please contact your KOMATSU distributor.
  • Page 264 KOMATSU genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your KOMATSU distrib- utor of the machine serial number and check the latest part num- ber when ordering parts.
  • Page 265 4.3 Wear parts Maintenance Wear parts list Item Part No. Part Name Q'ty Replacement frequency Center edge Side edge Standard (Bolt) (18) type (Nut) (18) (Washer) (18) Center edge Side edge Long life Bolt on cutting edge (Bolt) (18) type (Nut) (18) (Washer)
  • Page 266 4.4 Fuel, coolant and lubricants Wear parts list Maintenance Fuel, coolant and lubricants KOMATSU genuine oils are adjusted to maintain the reliabil- ity and durability of KOMATSU construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
  • Page 267 4.4 Fuel, coolant and lubricants Maintenance Wear parts list Be sure to check Total Basic Number (TBN) of oil frequently by TBN handy checker etc., and change oil based on the result. Always be aware that oil change interval is extremely shorter than standard.
  • Page 268 4.4 Fuel, coolant and lubricants Lubrication chart Maintenance 4.4.1 Lubrication chart 1. Lubrication intervals are based on the service meter reading. 2. Abbreviations: EO = Engine Oil, G = Lithium Grease No. 2, F = Diesel Fuel, AXO = Axle Oil, HO = Hydraulic Oil. 3.
  • Page 269 Use of fuel, coolant and lubricants according to ambient temperature 4.4.2 Use of fuel, coolant and lubricants according to ambient temperature Ambient Temperature Recommended Reservoir Fluid Type 104 122 °F KOMATSU Fluids °C KOMATSU (Note 1) EOS0W30 KOMATSU (Note 1) EOS5W40 KOMATSU Engine oil pan...
  • Page 270 HTHS (High-Temperature High-Shear Viscosity 150°C), speci- fied by ASTM D4741 must be equal to or higher than 3.5 mPa-S. KOMATSU EOS0W30 and EOS5W40 are the most suitable oils. Note 2: Power train of oil has different properties from engine oil. Be sure to use the recommended oil.
  • Page 271 4.4 Fuel, coolant and lubricants Maintenance Use of fuel, coolant and lubricants according to ambient temperature 2. For details of the ratio when diluting super coolant with water, see "Clean inside of cooling system (4-35)". Supercoolant AF-NAC may be supplied in premix. In this case, always top off with premix solution (never dilute with water).
  • Page 272 4.4 Fuel, coolant and lubricants Recommended brands, recommended quality for products other than KOMATSU genuine oil Maintenance 4.4.3 Recommended brands, recommended quality for products other than KOMATSU genuine oil When using commercially available oils other than KOMATSU genuine oil, or when checking the latest specifications, refer to the KOMATSU web page or consult your KOMATSU distributor.
  • Page 273 Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, always use a KOMATSU genuine part of the same size as the part that was replaced. Tightening torque...
  • Page 274 4.5 Standard tightening torques for bolts and nuts Torque list Maintenance Tightening torque Width Nominal - No. across of threads Target value Permissible range flats (b) (mm) kgfm lbft kgfm lbft 9/16 -18UNF 32.5 35 - 63 3.5 - 6.5 25.3 - 47.0 11/16 -16UN 54.2...
  • Page 275 Tighten a loosened clamp or replace a defective hose, as required. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your KOMATSU distributor to replace the critical parts. 4-25 WA470-6H – VEAM946100...
  • Page 276 4.6 Periodic replacement of safety critical parts Torque list Maintenance Safety critical parts for periodic replacement Q'ty Replacement interval Fuel hose (fuel tank - hand pump) Over flow hose (supply pump - fuel tank) Spill hose (injector nozzle - fuel tank) Steering hose (steering cylinder - tube) Steering hose (steering valve - stop valve) Steering hose (stop valve drain - centralized drain block)
  • Page 277 4.7 Maintenance schedule chart Maintenance Maintenance schedule chart Maintenance schedule chart 4.7.1 Maintenance schedule chart Service procedure see page 4.9.1 Initial 50 hours service (only after the first 50 hours) 4-31 Check for loose wheel hub bolts, tighten 4-31 4.9.2 Initial 250 hours service (only after the first 250 hours) 4-31 Replace transmission oil filter cartridge...
  • Page 278 4.7 Maintenance schedule chart Maintenance schedule chart Maintenance Service procedure see page 4.9.8 Every 250 hours service 4-58 Check battery electrolyte level 4-58 Check parking brake 4-61 Check alternator belt tension, adjust 4-61 Check air conditioner compressor belt tension, adjust 4-63 Check for loose wheel hub bolts, tighten 4-65...
  • Page 279 4.7 Maintenance schedule chart Maintenance Maintenance schedule chart Service procedure see page 4.9.12 Every 4000 hours service 4-86 Lubricating 4-86 Check water pump 4-87 Check air conditioner compressor, adjust 4-87 Check for loose engine high-pressure piping clamps, hardening of rubber 4-88 Checking for missing fuel spray prevention cap, hardening of rubber 4-88...
  • Page 280 Replace injector assembly Check the exhaust gas color visually. If there is any abnormality in the exhaust gas color, please ask your KOMATSU distributor to carry out inspection or replacement. For details of the proce- dure if any abnormality is found, see "Engine (3-176)".
  • Page 281 4.9 Service procedure Maintenance Initial 50 hours service (only after the first 50 hours) Service procedure 4.9.1 Initial 50 hours service (only after the first 50 hours) Carry out the following maintenance only after the first 50 hours. Check for loose wheel hub bolts, tighten If wheel hub nuts (1) are loose, tire wear will be increased and may cause accidents.
  • Page 282 4.9 Service procedure When required Maintenance 4.9.4 When required Clean, replace air cleaner element For inspection method, see "Check air cleaner element (3-96)". When the yellow piston of the dust indicator enters the red range (7.5 kPa) or the air cleaner clogging caution lamp of the machine monitor lights up, clean the air cleaner element.
  • Page 283 4.9 Service procedure Maintenance When required 4. Clean the interior of the air cleaner body, cover (3) and evac- uator valve (6). GK032240 NOTE The inner element must not be used again even after its clean- ing. When replacing the inner element, replace the outer ele- ment at the same time.
  • Page 284 4.9 Service procedure When required Maintenance Replacing element 1. Open the engine side cover on the right side of the machine. 2. Remove three clips (2), then remove cover (3). GK047015 3. Remove outer element (4). Do not remove inner element (5) at this time, however. GK032239 4.
  • Page 285 Cleaning inside of cooling Adding corrosion Kind of coolant system and changing coolant resistor KOMATSU supercoolant Every two years or every 4000 unnecessary (AF-NAC) hourswhichever comes first Every 1000 hoursand when clean-...
  • Page 286 To maintain the anticorrosion properties of Supercoolant (AF- NAC), always keep the density of Supercoolant between 30% and 68%. When using KOMATSU Supercoolant (AF-NAC), there is no need to use a corrosion resistor. When no corrosion resistor is used, use the special cover (600- 411-9000).
  • Page 287 Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your KOMATSU distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.
  • Page 288 4.9 Service procedure When required Maintenance 4. Set a container in position to catch the drained antifreeze mixture, then open drain valve (4) under the left side of the fuel tank and drain plug (5) at the side of cylinder block, and drain the coolant.
  • Page 289 4.9 Service procedure Maintenance When required Check transmission oil level, add oil WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the tempera- ture to go down before starting the work. Carry out this procedure if there is any sign of oil on the trans- mission case, or if there is oil mixed with the cooling water.
  • Page 290 4.9 Service procedure When required Maintenance Check axle oil level, add oil WARNING When checking the oil level, apply the parking brake and secure the front and rear frames with the safety bar. After stopping the engine, the parts and oil are at a high tem- perature.
  • Page 291 4.9 Service procedure Maintenance When required Clean axle case breather WARNING When cleaning the axle breather, apply the parking brake and secure the front and rear frames with the safety bar. A: Front B: Rear Remove all mud and dirt from around the breather with a brush. After removing the mud or dirt from around the breather, remove GK043063 the breather, immerse it in cleaning fluid and clean it.
  • Page 292 4.9 Service procedure When required Maintenance Clean air conditioner condenser WARNING Do not wash the condenser with a steam cleaner. There is danger that the condenser could overheat. If high-pressure water hits your body directly or dirt is sent flying, there is danger of personal injury. Always wear pro- tective glasses, dust mask, and other protective equipment.
  • Page 293 4.9 Service procedure Maintenance When required Check window washing fluid level, add fluid Check the washing fluid levels in washer tank (1). When the fluid has run low, add automotive window washing fluid. Be careful not to let dust get into the fluid. GK043058 Clean radiator fins and cooler fins WARNING...
  • Page 294 4.9 Service procedure When required Maintenance Manual fan reversing method NOTE Never rotate the fan in reverse by hand when carrying out the operation. Before operating the fan reverse rotation switch, run the engine at low idling. 1. Set the directional lever to the Neutral position. 2.
  • Page 295 4.9 Service procedure Maintenance When required 9. After the cooling fan reverse rotation pilot lamp on the machine monitor flashes, check that it goes out. The fan is set to rotate in the normal direction. 10. Run the engine at low idling for approx. 10 seconds. Auto reverse function (Option) GK043111...
  • Page 296 4.9 Service procedure When required Maintenance Clean fins with compressed air When cleaning the fins, insert a steam spray nozzle through the gaps between the radiator (1), oil cooler (2), and the aftercooler and condenser (3) of air conditioner. NOTE If the steam jet nozzle is brought too close to the radiator fins, it may damage the fins, so keep the nozzle a suitable distance away from the fins when cleaning.
  • Page 297 4.9 Service procedure Maintenance When required Turn, replace bolt on cutting edge WARNING It is extremely dangerous if the work equipment moves when carrying out the turning or replacement operation. Set the work equipment in a stable position, stop the engine, then set the safety lock lever securely to the LOCK position.
  • Page 298 4.9 Service procedure When required Maintenance Replace bucket teeth Bucket with tip tooth (Option) CAUTION If the pin is hit out with strong force, there is danger that the pin may fly out. Check that there is no one in the surrounding area.
  • Page 299 4.9 Service procedure Maintenance When required Check air conditioner Check level of refrigerant (gas) WARNING If the refrigerant of the conditioner system gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant.
  • Page 300 4.9 Service procedure When required Maintenance Maintenance and inspection and time to execute them Maintenance interval Inspection Item to check for location Check before Replacement 6 months operating interval Filter Clogging, dirt Carry out check 2 years Condenser Clogging, dirt Carry out check Belt Looseness, damage...
  • Page 301 4.9 Service procedure Maintenance When required Replace slow blow fuse NOTE Always turn the power OFF when replacing the slow blow fuse (turn the starting switch to the OFF position (A)). Always replace the slow blow fuse with a fuse of the same capacity.
  • Page 302 If there is no change in the up-and-down movement of the machine, the gas pressure in the accumulator has probably dropped. Please contact your KOMATSU distributor to have the accumu- lator inspected. REMARK Carry out the inspection with the speed range set to 2 - 4, with the machine traveling at a speed of at least 5 km/h.
  • Page 303 Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the following table. Since the travel speed indicated on the speedometer varies with the tire size, consult your KOMATSU distributor when using optional tires. Tire size...
  • Page 304 4.9 Service procedure When required Maintenance Check inflation pressure of tires WARNING When inflating a tire, check that no one will enter the working area. Use an air chuck which has a clip and which can be fixed to the air valve. While inflating the tire, check the inflation pressure occasionally so that it will not rise too high.
  • Page 305 4.9 Service procedure Maintenance Check before starting 4.9.5 Check before starting Check before starting For the following items, see "Check before starting (3-91)". Check monitor panel Check coolant level, add coolant Check oil level in engine oil pan, add oil Check fuel level, add fuel Check electric wiring Check parking brake...
  • Page 306 4.9 Service procedure Every 100 hours service Maintenance 4.9.7 Every 100 hours service Maintenance for every 50 hours service should be carried out at the same time. Lubricate rear axle pivot pin (3 places) 1. Using a grease pump, pump in grease through the grease fittings marked by the arrows.
  • Page 307 4.9 Service procedure Maintenance Every 100 hours service Clean element in air conditioner fresh air filter WARNING If compressed air is used, there is danger that dirt may fly and cause personal injury. Always wear safety glasses, dust mask, and other protective equipment.
  • Page 308 4.9 Service procedure Every 250 hours service Maintenance 4.9.8 Every 250 hours service Maintenance for every 50 and 100 hours service should be car- ried out at the same time. Check battery electrolyte level Carry out this check before operating the machine. WARNING Do not use the battery if the battery electrolyte level is below the (MINIMUM) LOWER LEVEL line.
  • Page 309 UPPER LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your KOMATSU distributor or battery maker. 4-59 WA470-6H – VEAM946100...
  • Page 310 Neutral- ize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your KOMATSU distributor or battery maker. When it is possible to use indicator to check electrolyte level If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
  • Page 311 1. Set the machine on a dry downhill slope, press the parking brake switch to the ON position, and check if the parking brake hold the machine in position. 2. If any problem is found, please contact your KOMATSU dis- tributor. GK038008 Check alternator belt tension, adjust Before starting the operation, or remove cover (1).
  • Page 312 GK047042 belt is not touching the bottom of the V-groove. In case any of the following occurs, ask the KOMATSU dis- tributor in your territory to replace the belts with new ones. The fan belt has elongated, leaving little allowance for adjustment.
  • Page 313 4.9 Service procedure Maintenance Every 250 hours service Check air conditioner compressor belt tension, adjust Before starting the operation, or remove cover (1). Checking GK047038 GK047038 The standard deflection between the air conditioner compressor pulley and crank pulley when pressed with a thumb (approx. 98 N) should be approx.
  • Page 314 V-groove. GK047044 In case any of the following occurs, ask the KOMATSU dis- tributor in your territory to replace the belts with new ones. The fan belt has elongated, leaving little allowance for adjustment.
  • Page 315 4.9 Service procedure Maintenance Every 250 hours service Check for loose wheel hub bolts, tighten If wheel hub nuts (1) are loose, tire wear will be increased and may cause accidents. 1. Check for loose nuts, and tighten if necessary. When checking for loose nuts, always turn the nuts in the direction of tightening to check.
  • Page 316 " brake has been depressed 5 or less times, the gas pres- sure in the accumulator has probably dropped. Please contact your KOMATSU distributor to have the accumu- lator inspected. REMARK Carry out the check within 5 minutes after stopping the engine. If...
  • Page 317 4.9 Service procedure Maintenance Every 250 hours service Lubricating NOTE On jobsites where there is a lot of heavy-duty work, or on job- sites where operations are carried out continuously for more than eight hours, reduce the greasing interval and carry out greasing more frequently.
  • Page 318 4. Loosen drain plug (P) and drain the oil. Be careful not to get oil on yourself. 5. Check the drained oil, and if there are excessive metal parti- cles or foreign material, please contact your KOMATSU dis- tributor. 6. Tighten drain plug (P).
  • Page 319 4.9 Service procedure Maintenance Every 500 hours service 10. After replacing the filter cartridge, add oil through oil filler (F) until the oil level is between the H and L marks on the dip- stick (G). 11. Run the engine at idling for short time, then stop the engine, and check that the oil is between the H and L marks on the dipstick.
  • Page 320 If any part other than a genuine KOMATSU filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
  • Page 321 4.9 Service procedure Maintenance Every 500 hours service 6. Install cup (2) to the bottom of the new fuel pre-filter car- tridge. When doing this, always replace the seal ring with a new part. Tightening torque for cup: 10 Nm When replacing the seal ring, coat the surface with clean fuel before installing it.
  • Page 322 If any part other than a genuine KOMATSU filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
  • Page 323 4.9 Service procedure Maintenance Every 1000 hours service NOTE Do not fill the filter cartridge with fuel. Cap (A) is installed to prevent dirt from entering the inside of the filter cartridge. 4. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn.
  • Page 324 4.9 Service procedure Every 1000 hours service Maintenance Change oil in transmission case and transmission oil filter cartridge, clean strainer WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
  • Page 325 4.9 Service procedure Maintenance Every 1000 hours service 12. Refill the specified quantity of oil through oil filler (F). 13. After filling with oil, check that the oil is at the specified level. For details, see "Check transmission oil level, add oil (4-39)". 14.
  • Page 326 4. Drive shaft center support (1 place) GK043202 Check of engine air intake piping clamps for looseness Please ask your KOMATSU distributor to check the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. Replace corrosion resistor cartridge 1.
  • Page 327 4.9 Service procedure Maintenance Every 2000 hours service 4.9.11 Every 2000 hours service Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time. Change oil in hydraulic tank, replace hydraulic filter element WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns.
  • Page 328 4.9 Service procedure Every 2000 hours service Maintenance 9. Remove mounting bolts (8) of filter cover (7) at the top of the tank, then remove the cover. When the cover is removed, the force of spring (9) may make the cover fly off, so keep the cover pushed down when removing the bolts.
  • Page 329 4.9 Service procedure Maintenance Every 2000 hours service 20. Next, operate the steering, bucket, and lift arm cylinders fully 3 - 4 times, then stop the engine and loosen air bleed plug (16). After bleeding the air from the hydraulic tank, tighten plug (16).
  • Page 330 4.9 Service procedure Every 2000 hours service Maintenance Replace hydraulic tank breather element WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
  • Page 331 4.9 Service procedure Maintenance Every 2000 hours service Change axle oil WARNING When changing the oil, apply the parking brake and secure the front and rear frames with the safety bar. After the engine is stopped, the parts and oil are at high tem- perature, and may cause burns.
  • Page 332 Permitted wear limit (B) of the disc is the point where groove (E) of the rod is in line with end face (D) of the guide. When this point is reached, please ask your KOMATSU dis- tributor to carry out inspection and replacement of parts.
  • Page 333 4.9 Service procedure Maintenance Every 2000 hours service If the disc is near the wear limit, carry out inspection at shorter intervals, regardless of the specified inspection inter- val. 4. Install cap nut (1). Tightening torque: 29.4 to 39.2 Nm REMARK On new machines, the position of the guide is adjusted so that the end face of rod (2) comes to the end face of guide (3).
  • Page 334 GK043216 If the work equipment stops while it is moving, the gas pressure in the accumulator has probably dropped. Please contact your KOMATSU distributor to have the accumu- lator inspected. Replace the accumulator every 4000 hours or every 2 years.
  • Page 335 KOMATSU distributor for service. Check vibration damper Check that there are no cracks or peeling in the outside surface of the rubber. If any cracks or peeling are found, contact your KOMATSU dis- tributor to have the parts replaced. 4-85 WA470-6H – VEAM946100...
  • Page 336 4.9 Service procedure Every 4000 hours service Maintenance 4.9.12 Every 4000 hours service Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time. Lubricating Carry out the greasing once every two years, regardless of whether the 4000 hour interval has passed.
  • Page 337 GK043220 Check water pump Check the water pump and its relative parts for water leak, and if anything abnormal is found, call on your KOMATSU distributor for repairs or replacement. Check air conditioner compressor, adjust As special tool is required for checking and adjusting the parts, request KOMATSU distributor for service.
  • Page 338 Check for any missing fuel spray prevention caps (1) to (11) or fuel spray prevention cover (12), and check also for any hard- ened rubber portions. If there are any missing caps or cover or the rubber is hardened, please contact your KOMATSU distribu- tor for repairs. 4-88...
  • Page 339 4.9 Service procedure Maintenance Every 8000 hours service Check starting motor Contact your KOMATSU distributor to have the starting motor checked. If the engine is started frequently, have this inspection carried out every 1000 hours. 4.9.13 Every 8000 hours service Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time.
  • Page 340 4.9 Service procedure Every 12000 hours service Maintenance 4-90 WA470-6H – VEAM946100...
  • Page 341 Technical Data 5. Technical Data WA470-6H – VEAM946100...
  • Page 342 Operating weight (including 1 operator: 80 kg) 22,910 (with bolt on cutting edge). Normal load 6,970 Bucket capacity Heaped m³ 4.1 (5.4) Engine model KOMATSU SAA6D125E-5 diesen engine kW (HP)/ Flywheel horsepower 203 (272)/2,000 Overall length 8,970 Overall height 3,470 Max. dimension when shaking bucket 5,975...
  • Page 343 Technical Data 5.1 Technical data GK032301 WA470-6H – VEAM946100...
  • Page 344 5.2 Noise emission levels Technical Data 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 ISO6396 (Dynamic test method, simulated working cycle). Sound power level emitted by the machine, measured according to ISO 6395 (Dynamic test method, simulated working cycle).
  • Page 345 Technical Data 5.3 Vibration level Vibration level When used for its intended purpose, levels of vibration for the earthworking machine transmitted from the operator's seat are lower or equal to the test vibrations for the relative machinery class in compliance with ISO 7096. The actual accelaration value of the upper limbs is less than 2.5 m/s².
  • Page 346 5.3 Vibration level Technical Data 6. Adjust the machine speed and travel path to minimize the vibration level When pushing with bucket or blade, avoid sudden load- " ing; load gradually Drive around obstacles and rough terrain conditions " Slow down when it is necessary to go over rough terrain "...
  • Page 347 Technical Data 5.4 Limit values for slopes Limit values for slopes Maximum slope angle for machine operation If operating the machine on a slope, its angle must not exceed 26° uphill, 35° downhill or 16° sideways. If you angle the machine at more than 35°...
  • Page 348 5.4 Limit values for slopes Technical Data WA470-6H – VEAM946100...
  • Page 349 Attachments, Options 6. Attachments, Options WARNING Please read and make sure that you understand the SAFETY section before reading this section. WA470-6H – VEAM946100...
  • Page 350 Ground with many light 3.8 m³ 26.5-25-20PR (L3 Rock) rocks Soft ground with many light 26.5-25-20PR (L3 Rock) rocks BOC indicates a bolt-on type cutting edge. When installing optional tires, please contact your KOMATSU distributor. WA470-6H – VEAM946100...
  • Page 351 Attachments, Options 6.2 Handling torque converter lock-up Handling torque converter lock-up WARNING When traveling down slopes of a grade of more than 6°, never depress the accelerator pedal fully, regardless of whether the torque converter lock-up switch is ON or OFF. It is extremely dangerous to drive too fast.
  • Page 352 6.2 Handling torque converter lock-up Attachments, Options 6.2.1 General locations GK038098 (1) Torque converter lock-up switch (2) Torque converter lock-up pilot lamp (3) Shift indicator (displays actual speed range) (4) Character display 1. Torque converter lock-up switch This switch (1) is the control switch for the torque converter lock- up function.
  • Page 353 Attachments, Options 6.2 Handling torque converter lock-up 3. Shift indicator For details, see "Shift indicator (3-29)" GK043113 4. Character display E 0 0 For details, see "Character display portion (3-10)" O V E R R U N P R O T E C T WA470-6H –...
  • Page 354 6.2 Handling torque converter lock-up Attachments, Options 6.2.2 Method of operation 1. Press the top (a) of the torque converter lock-up switch to turn it ON. The pilot lamp inside the switch lights up. 2. When the actual speed range is 3rd or 4th in either FOR- WARD or REVERSE, the torque converter lock-up function is actuated according to the travel speed and sets to direct drive.
  • Page 355 Attachments, Options 6.2 Handling torque converter lock-up 6.2.3 Warning/limit functions for travel speed Travel speed warning function (This functions even when the torque converter lock-up switch is OFF.) When the travel speed goes above 40 km/h {36.9 km/h}, the central warning lamp lights up and the alarm buzzer sounds. At the same time, “E00 OVERRUN PROTECT“...
  • Page 356 KOMTRAX equipment or to carry out action to stop communica- tions. If you do not obey the above precautions, neither KOMATSU nor your KOMATSU distributor can take any responsibility for any problem that is caused or for any loss that results.
  • Page 357 This may cause failure or fire on the KOMTRAX equipment or the machine itself. (Your KOMATSU distributor will carry out removal and installation of KOMTRAX.) Do not allow cables or cords to become caught; do not dam- age or pull cables or cords by force.
  • Page 358 6.4 Joystick steering system Attachments, Options Joystick steering system To enable you to use the joystick steering safely and efficiently, please read the following before using it. 6.4.1 Components GK043182 (1) Shift up switch (2) Shift down switch (3) FNR switch (4) Joystick steering lever (5) Joystick ON/OFF switch (6) HI/LOW selector switch...
  • Page 359 Attachments, Options 6.4 Joystick steering system 1. Shift up, shift down switch This switches (1) an (2) are used when shifting up or down, regardless of whether the transmission is in the manual shift mode or auto shift mode. Press (1): Shift up Press (2): Shift down GK043183 2.
  • Page 360 6.4 Joystick steering system Attachments, Options 5. HI/LOW Selector switch This switch (6) is used to switch the steering speed between HIGH and LOW. Position (a): HI The articulating speed of the machine is high in relationship to the operation of the joystick, so this setting is suitable for com- paratively fast cycle times.
  • Page 361 Attachments, Options 6.4 Joystick steering system 6.4.2 Structure and function The joystick steering system is a system used to steer wheel loaders with a lever instead of a steering wheel. The joystick enables steering with small, light movements, and helps to reduce operator fatigue. When joystick ON/OFF switch (1) is turned ON, it becomes pos- sible to operate the steering with the joystick.
  • Page 362 6.4 Joystick steering system Attachments, Options Operation using joystick lever and operation using steering wheel CAUTION If the directional lever and joystick FNR switch are not at the neutral position, the neutral interlock circuit makes it impos- sible to switch the transmission directional control (when the joystick ON/OFF switch is ON, it is switched from the direc- tional lever to the joystick FNR switch;...
  • Page 363 Attachments, Options 6.4 Joystick steering system Getting in or out WARNING Always spring the joystick console up before getting in or out of the operator's cab. If the console is sprung up, the safety switch is turned OFF and the joystick is automatically stopped from operating. The joystick console is a spring-up type to make it easier for the operator to get in and out of the operator's cab.
  • Page 364 6.4 Joystick steering system Attachments, Options Adjustment of joystick console WARNING Stop the machine on level ground in a safe place when car- rying out the adjustment. Carry out the adjustment before starting operations or when changing operator shifts. Put your back against the backrest of the operator's seat and adjust the seat so that it is possible to depress the brake fully, then adjust the console.
  • Page 365 Attachments, Options 6.4 Joystick steering system 6.4.3 Operation method of joystick steering system WARNING It is dangerous to turn the machine suddenly at high speed, or to turn on steep hills. Do not operate the steering in such conditions. When turning, the articulation stops at the position where the steering wheel is turned to, but if the joystick is held in the tilted position, the body will articulate fully.
  • Page 366 6.4 Joystick steering system Attachments, Options 3. Operate the joystick in direction (b) to turn the machine to the right; operate it in direction (a) to turn the machine to the left. The greater the angle of operation, the faster the articulating speed becomes.
  • Page 367 Attachments, Options 6.4 Joystick steering system REMARK The joystick steering is unstable and dangerous to operate at high speeds, so it is set so that the machine cannot travel in 4th. When joystick operation is selected, if the gearshift lever is moved to 4th, or the joystick ON/OFF switch is turned ON when the gearshift lever is at 4th, the central warning lamp lights up and the alarm buzzer sounds.
  • Page 368 6.5 Multi-function lever (with/without auxiliary control lever) Attachments, Options Multi-function lever (with/without auxiliary control lever) 6.5.1 Explanation of components NOTE Detail "A" shows machine equipment: multi-function lever with auxiliary control lever. GK043260 (1) Work equipment lever (2) Kickdown switch (3) Hold switch (7) Auxiliary control lever (4) FNR switch (5) Directional selector switch...
  • Page 369 Attachments, Options 6.5 Multi-function lever (with/without auxiliary control lever) 1. Work equipment lever Use this lever (1) to operate the lift arm and bucket. NOTE Do not use the FLOAT position when lowering the bucket. Use the FLOAT position when leveling, see "Leveling operation (3-134)".
  • Page 370 6.5 Multi-function lever (with/without auxiliary control lever) Attachments, Options 2. Kickdown switch When the gearshift lever is in 2nd, if switch (2) is pressed, the transmission will shift down to 1st. Use this when you need to increase the drawbar pull in digging operations.
  • Page 371 Attachments, Options 6.5 Multi-function lever (with/without auxiliary control lever) 4. Directional selector switch This switch (4) is used to switch the direction of travel of the machine between forward and reverse. F Position: FORWARD N Position: Neutral R Position: REVERSE Before operating this switch, check that the condition is as fol- GK032329 lows.
  • Page 372 6.5 Multi-function lever (with/without auxiliary control lever) Attachments, Options 7. Auxiliary control lever (adjacent to the multi-function lever) When multi-purpose bucket is used This lever (7) operates the multi-purpose bucket. Position (a): CLOSE Clam closes. Position (b): HOLD GK043259 The clam stops and remains in the same position. Position (c): OPEN Clam opens.
  • Page 373 Attachments, Options 6.5 Multi-function lever (with/without auxiliary control lever) 6.5.2 Operation Using switch to change between forward and reverse WARNING When changing direction between FORWARD REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so be particularly careful when changing direction to travel in reverse.
  • Page 374 6.5 Multi-function lever (with/without auxiliary control lever) Attachments, Options 3. Push the FNR switch on the head of the multi-function lever to the desired position. GK032329 If the directional selector pilot lamp on the machine monitor flashes, the switch or the lever is in one of the following condi- tions.
  • Page 375 Attachments, Options 6.6 3-lever control 3-lever control 6.6.1 Explanation of components GK043255 (1) Lift arm control lever (2) Bucket control lever (3) Auxiliary control lever 6-27 WA470-6H – VEAM946100...
  • Page 376 6.6 3-lever control Attachments, Options 1. Lift arm control lever (3-lever control) This lever (1) is used to operate the lift arm. NOTE Do not use the FLOAT position when lowering the bucket. Use the FLOAT position when leveling, see "Leveling operation (3-134)".
  • Page 377 Attachments, Options 6.6 3-lever control 3. Auxiliary control lever (3-lever control) When multi-purpose bucket is used This lever (3) operates the multi-purpose bucket. Position (a): CLOSE Clam closes. Position (b): HOLD The clam stops and remains in the same position. GK043258 Position (c): OPEN Clam opens.
  • Page 378 OK. If the mixer blades are not turning, no automatic lubrication is taking place. To eliminate the malfunction, contact your KOMATSU dealer. 6.7.2 Display and control unit The display and control unit is protected by a transparent plastic cover against splashing water and mechanical damage.
  • Page 379 Attachments, Options 6.7 Central lubrication system LED-display 1. Seven-segment display: Values and operating state 2. Pause time (PAUSE h/lmp) 3. Pump operation (CONTACT min/lmp) 4. Monitoring of system function by means of an external cycle switch (CS) 5. Monitoring of system function by means of an external pres- sure switch (PS) 6.
  • Page 380 6.7 Central lubrication system Attachments, Options 6.7.3 Changing the lubrication interval times The settings when shipping from factory are as follows: Greasing interval: after 1 hour Greasing time: 10 minutes. 6-32 WA470-6H – VEAM946100...
  • Page 381 Index 7. Index WA470-6H – VEAM946100...
  • Page 382 7.1 Index Index Index Cigarette lighter ......3-51 Control levers, explanation ....3-56 Accelerator pedal .
  • Page 383 KOMTRAX ......6-8 Air conditioner (automatic) ..4-42, 4-49, 4-63 KOWA (KOMATSU Oil Wear Analysis) ..4-7 Air conditioner (standard) ..4-42, 4-49, 4-63 Air conditioner compressor .
  • Page 384 7.1 Index Index Hydraulic oil ..... . 4-58, 4-77 Hydraulic tank breather ....4-80 Parking brake .
  • Page 385 Index 7.1 Index Serial no. plate Rear wiper switch ..... . 3-51 Axle ....... . 1-11 Rear working lamp switch .
  • Page 386 7.1 Index Index Work equipment Adjusting boom kickout ....3-140 Adjusting bucket positioner ....3-141 Bucket level indicator .
  • Page 387 Notes 8. Notes WA470-6H – VEAM946100...
  • Page 388 Notes WA470-6H – VEAM946100...
  • Page 389 Notes WA470-6H – VEAM946100...
  • Page 390 Notes WA470-6H – VEAM946100...
  • Page 391 Notes WA470-6H – VEAM946100...
  • Page 392 Notes WA470-6H – VEAM946100...

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