Page 1 Operation & Maintenance VENAM31500 Manual WA270 WHEEL LOADER SERIAL NUMBERS H75051 AND UP H83001 AND UP DANGER ORIGINAL INSTRUCTIONS Incorrect operation and maintenance of this machine may be hazardous and cause injuries. The operator and maintenance personnel must read this manual before commencing operation or maintenance.
Page 3 Komatsu or Ko- matsu approved rebuilt parts or assemblies or others parts of equivalent quality, and that the engine be serviced by an authorized Komatsu distribu- tor. Failure to follow these recommendations could result in ineffective serv- ice, damage to the product or safety risks (including personal injury or death).
Page 4: Eu Directives
(1) on the left side of the operator's seat. If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement.
Page 5 The transmitter unit must be spatially separated from the vehicle’s electronic system. • Make sure when installing the antenna that this is installed correctly with good earth connection between antenna and vehicle mass. Also observe Komatsu and manufacturer’s installation instructions for wiring, installation and maximum permit- ted power consumption.
Page 6: Safety Information
SAFETY INFORMATION FOREWORD SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 7: 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 ques- tions regarding information in this manual.
Page 8: Noise Emission Levels
NOISE EMISSION LEVELS FOREWORD NOISE EMISSION LEVELS A sign is attached to the machine that state the noise level produced. • Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A weighted emission sound pressure level at the operator's position is 2.5 dB, in accordance with ISO 11201.
Page 9: Vibration Level
FOREWORD VIBRATION LEVEL VIBRATION LEVEL When used for its intended purpose, levels of vibration for the earth working machine transmitted from the oper- ator’s seat are lower or equal to the test vibrations for the relative machinery class in compliance with ISO 7096. The actual acceleration value of the upper limbs is less than 2.5 m/s .
Page 10: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Digging work • Leveling work • Dozing work • Loading work For details of the work procedure, see “RECOMMENDED APPLICATIONS”.
Page 11: Engine Technology To Conform Exhaust Gas Emission
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union. • Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process to burn the soot is performed automatically to keep the filtering performance of KDPF high.
Page 12: Product Information
PRODUCT INFORMATION FOREWORD PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE This is located at the center of the front frame on the right side of the machine.
Page 13: Rops/Fops Serial Plate Location
ROPS/FOPS SERIAL PLATE LOCATION AXLE SERIAL PLATE LOCATION This plate is located on the right of front axle and on the left of rear axle. PRODUCED BY KOMATSU GERMANY GmbH, HANNOVER FEDERAL REPUBLIC OF GERMANY FOR Komatsu Ltd.,Tokyo,Japan MODEL PART NO.
Page 14: Seat Plate Location
PRODUCT INFORMATION FOREWORD SEAT PLATE LOCATION This plate is located in front of seat, covered by the bellows. FLUORINATED GREENHOUSE GASES Product contains fluorinated greenhouse gases. Product contains fluorinated greenhouse gases HFC-134a 1.43 1430 09971-10101 g0027100 SERVICE METER LOCATION It is at the center bottom of the machine monitor. 1-12...
Page 15: Your Machine Serial Numbers And Distributor
FOREWORD PRODUCT INFORMATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturer name Komatsu Germany GmbH Address Hanomag Strasse 9 30449 Hannover Germany Distributor name Address Phone/Fax Service personnel 1-13...
Page 16: Declaration Of Conformity
DECLARATION OF CONFORMITY FOREWORD DECLARATION OF CONFORMITY The manufacturer: Komatsu Germany GmbH Hanomag Straße 9 30449 Hannover Germany Declares that this machine: WA270-8* Fulfils all the relevant provisions of following EC Directives: Machine Directive 2006/42/EC Electro Magnetic Compatibility Directive 2004/108/EC until 19 April 2016...
Page 17: Retrofitting By Third-Party Suppliers
In the event of tools (e.g. loading shovels) being retrofitted by a third-party supplier, the technical specifications of the manufacturer must be taken into account. For this purpose, or for further information, please be sure to consult Komatsu or your local Komatsu dealer. 1-15...
Page 18: Explanation Of Acronyms
EXPLANATION OF ACRONYMS FOREWORD EXPLANATION OF ACRONYMS Acronyms Stand for: KDPF Komatsu Diesel Particulate Filter KVGT Komatsu Variable Geometry Turbo KCCV Komatsu Closed Crankcase Ventilation Selective Catalytic Reduction Diesel Exhaust Fluid ECSS Electrically Controlled Suspension System 1-16...
Page 19: Table Of Contents
FOREWORD TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 EU DIRECTIVES ..........................1-2 SAFETY INFORMATION .......................... 1-4 SAFETY LABELS ............................. 1-5 NOISE EMISSION LEVELS ........................1-6 VIBRATION LEVEL........................... 1-7 INTRODUCTION ............................1-8 MAIN USE OF MACHINE ........................1-8 DIRECTIONS OF MACHINE......................
Page 20 OTHER TROUBLE......................... 3-238 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................
Page 21 FOREWORD TABLE OF CONTENTS WELDING INSTRUCTIONS....................... 4-2 DO NOT DROP THINGS INSIDE MACHINE ..................4-2 PRECAUTIONS FOR KDPF ......................4-2 PRECAUTIONS FOR SCR ASSEMBLY .................... 4-3 DUSTY JOBSITES..........................4-3 AVOID MIXING OIL..........................4-3 LOCK INSPECTION COVERS ......................4-3 BLEED AIR FROM HYDRAULIC CIRCUIT ..................4-3 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES .............
Page 22 TABLE OF CONTENTS FOREWORD METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-7 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-8 INDEX................................8-1 1-20...
Page 23: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
Page 24 SAFETY SAFETY SAFETY SAFETY LABELS ............................2-4 LOCATION OF SAFETY LABELS......................2-5 CONTENTS OF SAFETY LABELS ......................2-7 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........... 2-15 PRECAUTIONS BEFORE STARTING OPERATION................2-15 ENSURE SAFE OPERATION ......................2-15 UNDERSTAND THE MACHINE ....................... 2-15 PREPARATIONS FOR SAFE OPERATION ....................
Page 25 SAFETY SAFETY PRECAUTIONS FOR TRANSPORTATION..................... 2-31 PRECAUTIONS WHEN LOADING AND UNLOADING ..............2-31 TOWING AND BEING TOWED....................... 2-32 PRECAUTIONS FOR TOWING AND BEING TOWED..............2-32 PRECAUTIONS FOR MAINTENANCE ......................2-33 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE .......... 2-33 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ........2-33 KEEP WORK PLACE CLEAN AND TIDY ..................
Page 26: Safety Labels
If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...
Page 27: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS...
Page 28 SAFETY LABELS SAFETY (1) Caution before operating (15) Caution for modification of ROPS/FOPS (2) Caution when leaving operator's seat (16) Prohibition of start by short-circuiting (3) Caution when traveling in reverse (17) Caution for cleaning cooler core (4) Caution for electric cables (18) Emergency escape (5) Prohibition of trespassing (19) Caution when closing emergency escape right...
Page 29: Contents Of Safety Labels
SAFETY SAFETY LABELS CONTENTS OF SAFETY LABELS Caution before operating “09651-A0481” • Warning! • Read manual before operation, maintenance, disassembly, assembly and transportation. Caution when leaving the operator's seat “09654-C0481” • Sign indicates a hazard of unexpected moving of stopped machine.
Page 30 SAFETY LABELS SAFETY WARNING To prevent SEVERE INJURY or DEATH, do the following before moving machine or its attachments: • Honk horn to alert people nearby. • Be sure no one is on or near the machine. • Use spotter if view is obstructed. Follow above even if the machine is equipped with back-up alarm and mirrors.
Page 31 SAFETY SAFETY LABELS Caution for frame lock bar “09161-C0641” • Sign indicates a crush hazard between the articulating parts of the vehicle. • Lock vehicle with lock bar to avoid movement during main- tenance and transportation. Caution for high-temperature coolant “09653-A0641”...
Page 32 SAFETY LABELS SAFETY Caution for handling battery cable “09808-A1201” • Sign indicates an electric hazard from handling the cable. • Read the operation and maintenance manual for safe and proper handling. Caution for explosion “09659-A057B” • Sign indicates an explosion hazard. •...
Page 33 SAFETY SAFETY LABELS Caution for nearing machine “09806–C1201” • Sign indicates a hazard of being run over by moving vehi- cle. • Keep a safe distance from vehicle when it is moving. Prohibition of entering beneath work equipment “09807-C1201” • Sign indicates a crush hazard from falling off of working de- vice.
Page 34 SAFETY LABELS SAFETY Prohibition of start by short-circuiting “09842-A0481” • 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 a serious bodily injury or fire.
Page 35 SAFETY SAFETY LABELS Caution when closing emergency escape right window “421-93-4990” Caution for high-temperature turbocharger “09817-A0753” • Sign indicates a burn hazard from touching heated parts, such as engine, motor, or muffler during or right after oper- ation. • Never touch when hot. Caution for hot exhaust pipe “09817-A0753”...
Page 36 SAFETY LABELS SAFETY Caution for handling battery “09664-62A11”, or “09664-62D11” • Sign indicates a hazard of battery. • Read the operation and maintenance manual for safe and proper handling. Caution when traveling in reverse (Machine with rearview camera) “09833-C0881” • When backing up, rear of machine is displayed on monitor.
Page 37: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 38: Precautions For Inside Operator's Compartment
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical compo- nents.
Page 39: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE PRECAUTIONS TO PREVENT FIRE ACTIONS IF FIRE OCCURS • Turn the starting switch to OFF position, and stop the engine. • Use the handrails and steps to escape from the machine. •...
Page 40: Precautions When Getting On Or Off Machine
Fire around the machine due to highly heated exhaust gas This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF). KDPF is a device to purify the soot in the exhaust gas. Exhaust gas temperature may increase during the purifi- cation process (regeneration).
Page 41: No Jumping On Or Off Machine
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • Do not get on or off the machine with tools in your hand. NO JUMPING ON OR OFF MACHINE Getting on or off the moving machine can cause serious personal injury or death. Always observe the following. •...
Page 42: Do Not Get Caught
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY Whenever leaving the machine, be sure to lower the work equipment to the ground, lock the work equipment by pressing work equipment lock switch (1) (pilot lamp lights up) and stop the engine by setting parking brake switch (2) to ON (opera- tion) position (A).
Page 43: Unauthorized Modification
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
Page 44: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 45: Ensure Good Visibility
SAFETY PRECAUTIONS FOR OPERATION Voltage of Cables Safety Distance 154000 V Min. 5 m 187000 V Min. 6 m 275000 V Min. 7 m 500000 V Min. 11 m • To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera- tor's seat, and be careful not to touch the chassis with any exposed part of your body.
Page 46: Start Engine
Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. START ENGINE USE WARNING TAGS If there is a “DANGER! Do NOT operate!”...
Page 47: Precautions When Starting Engine
SAFETY PRECAUTIONS FOR OPERATION • Check the coolant level, fuel level, DEF level, and oil level in engine oil pan, check for clogging of the air cleaner, and check for damage to the electric wiring. • Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake pedal, and check that the pedals work properly.
Page 48: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cables. • When connecting a normal machine to a failed machine with the jumper cables, always use the normal machine with the same battery voltage as the failed machine.
Page 49: Precautions When Traveling
SAFETY PRECAUTIONS FOR OPERATION • Prohibit other personnel to get on the machine. • If there are any persons in the area around the machine, there is danger that they may be hit or caught by the ma- chine, and this may lead to serious personal injury or death.
Page 50: Precautions When Traveling On Slopes
PRECAUTIONS FOR OPERATION SAFETY • If you drive the machine at high speed continuously for a long time, the tires will overheat and the internal pressure will become abnormally high. This may cause the tires to burst. If a tire bursts, it produces a large destructive force, and this may cause serious injury or death.
Page 51: Precautions When Operating Machine
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN OPERATING MACHINE • When using the machine, to prevent serious personal injury or death caused by the work equipment or by the machine tipping over due to overloading, do not use the machine beyond the permitted performance of the machine such as the maximum permitted load for the structure of the machine.
Page 52: Precautions When Operating On Snow Or Frozen Surfaces
PRECAUTIONS FOR OPERATION SAFETY • Do not dig the work face under an overhangs. There is a danger that the work face will collapse. • When digging, never thrust the bucket into a load at an an- gle. This will bring an excessive load on the machine and will reduce the machine life.
Page 53: Precautions For Transportation
• This machine needs to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. • Lock the frame with the frame lock bar to prevent the machine from articulating.
Page 54: Towing And Being Towed
PRECAUTIONS FOR OPERATION SAFETY • Always use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough to provide a safe loading slope. Take suitable steps to prevent the ramps from moving out of position or coming off. (1) Chocks (2) Ramp (3) Width of ramps: Same width as tires...
Page 55: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the “DAN- GER! Do NOT operate!” warning tag. If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 56: Guards
END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death.
Page 57: Two Workers For Maintenance When Engine Is Running
When performing maintenance work, perform the after- treatment devices regeneration disable according to “HAN- DLE Komatsu Diesel Particulate Filter (KDPF) (3-124)”. • Lower the work equipment to the ground and press work equipment lock switch (1) to lock the work equipment (pilot lamp lights up) and prevent it from moving.
Page 58: Turn Off Ecss Switch Before Performing Inspection And Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY TURN OFF ECSS SWITCH BEFORE PERFORMING INSPECTION AND MAINTE- NANCE Before starting the inspection and maintenance, lower the bucket to the ground and turn the ECSS switch to OFF position, then stop the engine. Never turn the ECSS switch to ON position during the inspection or maintenance.
Page 59: Precautions For Check And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE USE PROPER TOOLS Use the tools suited to the task and use them correctly. Using damaged, deformed, or low quality tools, or making improper use of the tools may cause serious personal injury or death. PRECAUTIONS FOR CHECK AND MAINTENANCE TURN BATTERY DISCONNECT SWITCH TO OFF POSITION In the following cases, turn the starting switch to OFF position and check that the system operating lamp is off.
Page 60: Precautions When Using Hammer
PRECAUTIONS FOR MAINTENANCE SAFETY Danger from dilute sulphuric acid When the battery is being charged, flammable hydrogen gas is generated and may explode. In addition, the battery electrolyte includes dilute sulphuric acid. Any mistake in handling may cause serious personal injury, explosion, or fire. Always ob- serve the following.
Page 61: Precautions For High-Temperature Oil
If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 62: Precautions For Noise
• When disposing of the accumulator, the gas must be re- leased. Ask your Komatsu distributor to perform this work. PRECAUTIONS FOR COMPRESSED AIR • When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by flying dust or particles.
Page 63: Tires
To ensure safety, always observe the following. • Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special tech- nology, so always ask your Komatsu distributor to perform these operations. • Use only specified tires and inflate them to the specified pressure.
Page 64: Precautions For Storing Tires
PRECAUTIONS FOR MAINTENANCE SAFETY • If the rim parts are not fitted properly when the tire is being pumped up, there is a danger that the rim parts may fly off, so set up a protective fence around the tire, and do not stand directly in front of the rim. Stand beside the tread when pumping up the tire.
Page 65: Precautions For Def
SAFETY PRECAUTIONS FOR DEF PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...
Page 67: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 68: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Bucket (11) Rear wheel (2) Front wheel (12) Stepladder (3) Bell crank (13) Lift cylinder (4) Bucket cylinder (14) Boom (5) Turn signal lamp (15) Rear working lamp (6) Headlamp (16) Rearview camera (7) Rearview mirror (17) Rear combination lamp (8) Front working lamp...
Page 69: Controls And Gauges Names
OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES (1) Front switch panel (9) Turn signal lever (2) Directional lever (9) Dimmer switch (3) Engine shutdown secondary switch (10) Parking brake switch (4) Hazard lamp switch (11) Monitor switch (5) Speed range selector switch (12) Cigarette lighter (6) Machine monitor (13) Rearview monitor brightness adjustment switch...
Page 70 GENERAL VIEW OPERATION (17) Directional selector switch (24) Rear wiper switch (18) Multifunction mono-lever (25) Steering tilt lock lever (19) PCS (Proportional Control Switch) (if equipped) (26) L.H. brake pedal (20) Accelerator pedal (27) Max. traction switch (21) R.H. brake pedal (28) Room lamp switch (22) Starting switch (29) Rear heated wire glass switch...
Page 71 OPERATION GENERAL VIEW MACHINE MONITOR EQUIPMENT NAME General view (A) LCD unit (C) Meter unit (B) LED unit (1) HST oil temperature gauge (15) Engine tachometer (2) HST oil temperature caution lamp (16) Speedometer (3) Engine coolant temperature caution lamp (17) Fuel level caution lamp (4) Engine coolant temperature gauge (18) Fuel gauge...
Page 72 GENERAL VIEW OPERATION Display of liquid crystal unit (A) Standard screen (D) Warning screen (B) ECO guidance screen (E) User menu screen (C) Maintenance time warning screen (27) Message display (37) Preheating pilot lamp (28) Quick coupler lock release pilot lamp (if equipped) (38) Fan reverse rotation display (29) Directional selector pilot lamp (39) Secondary steering pilot lamp...
Page 73: Other Equipment Name
OPERATION GENERAL VIEW OTHER EQUIPMENT NAME Inside of cab (1) 24 V power supply (8) Cab door handle (2) Rearview monitor (9) Fuse (3) Ashtray (10) AUX (4) Open knob for alternate exit of cab (11) Unlock knob for slide window of cab (5) Cool box (12) Open handle for cab L.H.
Page 74 GENERAL VIEW OPERATION Outside of cab (1) Slow-blow fuse (2) Frame lock bar...
Page 75 (3) Towing pin (10) Battery disconnect switch (4) Backup alarm (11) System operating lamp (5) KDPF (12) DEF pump (6) DEF injector (13) DEF filter (7) SCR assembly (14) DEF tank (8) Dust indicator (9) Komatsu Closed Crankcase Ventilation (hereafter KCCV) ventilator...
Page 76: Explanation Of Components
EXPLANATION OF COMPONENTS OPERATION EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT FF: Failure display screen (A) Warning display...
Page 77 NOTICE If the lamps, alarm buzzer, etc. do not work, the machine monitor may be failed or the electric wiring may have breakage. In this case, ask your Komatsu distributor for repair. REMARK When the engine is started, the battery voltage may suddenly drop depending on the temperature and the bat- tery condition.
Page 78 5 seconds, and then screen goes out. End screen with message If there is any message from your Komatsu distributor, it is displayed on end screen DD for 5 seconds, and then the screen goes out. In this case, turn the starting switch to ON position to re-check the message, and if it is the message requesting response, send back your reply.
Page 79 Starting screen BB without inputting ID number. REMARK • Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identification function. • Depending on the set value of ID holding time, even if inputting ID number for operator identification func- tion is set, the ID number input screen LL (with SKIP) or MM (without SKIP) may not be displayed while the starting switch is turned to ON position.
Page 80 Be careful not to use it for the purpose of security enhance- ment. Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third person.
Page 81 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE If any trouble occurs during operation, the standard screen BB changes to the failure display screen FF. When ENTER switch is pressed while guidance icon (1) is dis- played, the “Current Abnormality”...
Page 82 EXPLANATION OF COMPONENTS OPERATION (1) HST oil temperature caution lamp (7) Seat belt caution lamp (2) Engine coolant temperature caution lamp (8) Action level (3) Warning display (9) Brake oil pressure caution lamp (4) Warning display (10) Fuel level caution lamp (5) Centralized warning lamp (11) DEF level caution lamp (6) Guidance icon...
Page 83 Stop the operation and move the machine to a Sounds in- Lights up Lights up safe place, then ask your Komatsu distributor for termittently in red inspection and maintenance. High If there is an overrun related display, reduce the engine speed and machine travel speed while ↑...
Page 84 (A) Caution lamp (B) Action level (C) Failure code Code to indicate the content of the failure. Notify it when calling your Komatsu distributor. (D) Failure name (E) Message Take appropriate remedies according to the displayed message. (F) Contact telephone number The telephone number of the contact such as your Komatsu distributor is displayed.
Page 85 OPERATION EXPLANATION OF COMPONENTS (G) Guidance icon On the “Current Abnormality” list screen, the following switches displayed in guidance icon (G) can be operated. UP switch: Moves to the previous page. When on the first page, it moves to the last page. DOWN switch: Moves to the next page.
Page 86 At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance. Action level is not displayed and lamp lights up in red If the brake oil pressure is below the specified value while the engine is stopped, the caution lamp lights up in red.
Page 87 The caution lamp lights up in yellow. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for the inspection and maintenance as needed. WORK EQUIPMENT SYSTEM CAUTION LAMP The work equipment system caution lamp warns about abnor- mality in the work equipment system.
Page 88 EXPLANATION OF COMPONENTS OPERATION DEF LEVEL CAUTION LAMP DEF level caution lamp alerts when DEF tank level becomes low. Whenever the caution lamp lights up in red, immediately add DEF. Fault conditions that result in activation of the Inducement strat- egy for engine derates to prompt to maintain or repair the emis- sion control system.
Page 89 The caution lamp lights up in yellow. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for the inspection and maintenance as needed. HST OIL FILTER CLOGGING CAUTION LAMP HST oil filter clogging caution lamp warns about clogging of the HST oil filter.
Page 90 The caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
Page 91 Whenever the caution lamp lights up in yellow, it is necessary to ask your Komatsu distributor to go off this caution lamp. When stopping the engine, stop it after running it at low idle for approximately 5 minutes. For details, see “METHOD FOR STOPPING ENGINE (3-181)”.
Page 92 EXPLANATION OF COMPONENTS OPERATION Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow. When you finish the operation, always perform the inspection and maintenance.
Page 93 Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for the inspection and maintenance as needed. 3-27...
Page 94 • By default, the maintenance time caution lamp (yellow) is set to light up when the remaining time reaches 30 hours. However, you can change this setting. To change the setting, ask your Komatsu distributor. CENTRALIZED WARNING LAMP The centralized warning lamp lights up in red and at the same time the alarm buzzer sounds intermittently when the machine is under the following condition.
Page 95 OPERATION EXPLANATION OF COMPONENTS Machine conditions under which centralized warn- Other monitor displays ing lamp lights up When action level L02, L03, or L04 is displayed on the machine monitor. When the engine overrun caution lamp is lit. When the brake oil pressure is below the specified The brake oil pressure caution lamp lights value while the engine is running.
Page 96 EXPLANATION OF COMPONENTS OPERATION When the starting switch is turned on and the display items are functioning, the pilot lamps light up. (1) Message display (12) Work equipment lock pilot lamp (2) Directional selector pilot lamp (12) Remote positioner display (3) ECSS pilot lamp (13) Shift lever position display (4) Air conditioner display...
Page 97 OPERATION EXPLANATION OF COMPONENTS Pop up display For some pilot lamps, pop-up (A) is displayed on the screen when they are selected. See the details of the pilot lamps shown below. TURN SIGNAL PILOT LAMP The turn signal pilot lamp flashes synchronously with the turn signal lamp, when it is turned on.
Page 98 EXPLANATION OF COMPONENTS OPERATION DIRECTIONAL SELECTOR PILOT LAMP The directional selector pilot lamp lights up in green when the directional selector switch is effective. It lights up in yellow when the directional selector switch is op- erated wrongly. It pops up when the directional selector switch actuation switch is turned on.
Page 99 MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. (A): There is unread message (B): There is any read message to which no reply is made. To read the message, see “MESSAGE DISPLAY (3-89)”.
Page 100 Also, keep combustible materials away from the exhaust pipe outlet to prevent a fire. • If there is a thatched roof, dead leaves, paper, or other combustible matter near the machine, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-124)”. Aftertreatment devices regeneration display indicates the re- generation state of the aftertreatment devices.
Page 101 OPERATION EXPLANATION OF COMPONENTS EMERGENCY HST PUMP DRIVE PILOT LAMP The emergency HST pump drive pilot lamp lights up when the emergency HST pump drive switch is turned on. At the same time, the alarm buzzer sounds intermittently. STEERING LOW OIL PRESSURE CAUTION LAMP Steering low oil pressure pilot pump lights up in red when the steering pressure is low.
Page 102 EXPLANATION OF COMPONENTS OPERATION WORK EQUIPMENT LOCK PILOT LAMP The work equipment lock pilot lamp lights up when the work equipment is locked. This pops up on the screen when the work equipment is switched from the unlock mode to the lock mode. PARKING BRAKE PILOT LAMP The parking brake pilot lamp lights up when the parking brake is applied.
Page 103 OPERATION EXPLANATION OF COMPONENTS GUIDANCE TO AVOID HYDRAULIC RELIEF If the hydraulic equipment is relieved for more than 8 seconds during operation, the hydraulic relief deterrence message is displayed on the monitor. The hydraulic equipment is relieved when an attempt is made to lengthen each cylinder further over the maximum (for exam- ple, to move bucket control lever to TILT while the bucket is fully tilted) or reduce it further over the minimum.
Page 104 EXPLANATION OF COMPONENTS OPERATION When the time until engine output power limitation starts is less than 1 hour “DEF refill caution will appear soon.” is displayed. DEF Level Low Error guidance goes out in more than 15 seconds or when ENTER switch is pressed. For the remaining amount of DEF, see “DEF LEVEL GAUGE (3-43)”.
Page 105 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY (1) HST oil temperature gauge (6) Speedometer (2) Engine coolant temperature gauge (7) DEF level gauge (3) ECO gauge (8) Variable speed display (4) Fuel gauge (9) R.H. meter (5) Engine tachometer (10) L.H. meter SPEEDOMETER The speedometer indicates the travel speed of the machine.
Page 106 EXPLANATION OF COMPONENTS OPERATION ENGINE COOLANT TEMPERATURE GAUGE Engine coolant temperature gauge shows the engine coolant temperature. When the indicator is in the white or green range during opera- tion, it is normal. If the indicator is in the red range, the engine coolant tempera- ture caution lamp lights up in red, and action level “L02”...
Page 107 OPERATION EXPLANATION OF COMPONENTS VARIABLE SPEED DISPLAY The variable speed display indicates the setting speed of travel speed control dial. (A): Speed range selection is 1st speed and maximum setting speed is lower than 4 km/h. (B): Speed range selection is 1st speed and maximum setting speed is 4 km/h or higher.
Page 108 EXPLANATION OF COMPONENTS OPERATION Service meter display Indicates the integrated operating hours of the machine. When the engine has run, the service meter advances even if the machine is not being operated. The service meter advances by 0.1 for 6 engine running mi- nutes and by 1 for 1 engine running hour, regardless of the en- gine speed.
Page 109 OPERATION EXPLANATION OF COMPONENTS Fuel consumption gauge display Indicates the average fuel consumption of the machine. (C): Average fuel consumption in a day (D): Split fuel consumption (under measuring) (E): Split fuel consumption (when measuring is stopped) REMARK Display on the fuel consumption gauge can be switched be- tween the average fuel consumption per day (from 0:00 am of the day to 0:00 am of the next day) and the average fuel con- sumption during an selected period (split fuel consumption).
Page 110 EXPLANATION OF COMPONENTS OPERATION The function of each switch varies depending on the screen of the machine monitor. (1) UP switch (5) RETURN switch (2) Air conditioner switch and numeric keypad (6) DOWN switch (3) Menu switch (7) Guidance icon (4) ENTER switch REMARK •...
Page 111 OPERATION EXPLANATION OF COMPONENTS MENU SWITCH When this switch is pressed on the standard screen, the follow- ing user menu screen is displayed. The user menu screen is not displayed during traveling. For the user menu, see “USER MENU (3-46)”. When normal: Displays the ECO guidance menu screen.
Page 112 EXPLANATION OF COMPONENTS OPERATION DOWN SWITCH Pressing DOWN switch moves the cursor down by one item. When on the last line, it moves to the first line. On the value input screen, the value is decreased by one. AIR CONDITIONER SWITCH AND NUMERIC KEYPAD The air conditioner switch and the numeric keypad which are used for the operation of the air conditioner consist of 10 switches.
Page 113 OPERATION EXPLANATION OF COMPONENTS (A) “Energy Saving Guidance” • Check of “Operation Records” • Check of “ECO Guidance Records” • Check and reset of “Average Fuel Consumption Record” • “Configurations” (B) “Machine Setting and Information” • Setting for “Manual Fan Reverse Mode” •...
Page 114 EXPLANATION OF COMPONENTS OPERATION (E) “Maintenance” • Check and reset of various maintenance remaining times (F) “Monitor Setting” • “Rearview Monitor Setting” • “Meter Display Selection” • “Screen Adjustment” • “Clock Adjustment” • “Language Setting” • “Operator ID” (G) Message Display •...
Page 115 OPERATION EXPLANATION OF COMPONENTS REMARK The default tab when the standard screen is changed to the user menu screen varies with the machine condi- tion. If multiple conditions are established simultaneously, the following priority is given. 1. SCR event occurs → “SCR Information” 2.
Page 116 EXPLANATION OF COMPONENTS OPERATION When “Average Fuel Consumption Display” is set to “1 Day” “1 Day” is displayed on the place shown with arrow in the fig- ure. When “Average Fuel Consumption Display” is set to “Split Time”, and split time is measured (A) Display during measurement (B) Date and time when measurement is started...
Page 117 OPERATION EXPLANATION OF COMPONENTS ECO GUIDANCE RECORD On “ECO Guidance Records” screen, the frequency of display of the ECO guidance on a daily basis or during the split meas- urement period and “Operational Advice” are displayed. Select ECO Guidance Records from Energy Saving Guidance menu screen, then press ENTER switch (1).
Page 118 EXPLANATION OF COMPONENTS OPERATION When display of “Average Fuel Consumption Display” is set to “Split Time”, and split time measurement is stopped (C) Display while measurement is stopped (D) Dates and times when the measurement is started and stopped To start the split time measurement, see the guidance icon and press ENTER switch (1).
Page 119 OPERATION EXPLANATION OF COMPONENTS • When display of the “Last 12 hours” is selected • When display of the “Last 7 days” is selected REMARK The graph of the “Last 12 hours” is updated every hour of the service meter reading. The graph of the “Last 7 days”...
Page 120 EXPLANATION OF COMPONENTS OPERATION DISPLAY SETTING On the “Configurations” menu, it is possible to perform follow- ing settings. • Setting “Average Fuel Consumption Display” • Switching ON/OFF of “ECO Gauge Display” • Setting “ECO Gauge Display Fuel Target Value” • Switching ON/OFF of ECO guidance •...
Page 121 OPERATION EXPLANATION OF COMPONENTS Select “1 Day” or “Split Time”, then press ENTER switch (1). The default is “1 Day”. To cancel, press RETURN switch (2). “1 Day” Displays the average fuel consumption in 1 day from 0:00 a.m. of the day to 0:00 a.m. of the next day. Reset at 0:00 a.m.
Page 122 EXPLANATION OF COMPONENTS OPERATION Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the ECO gauge. “OFF” Does not display the ECO gauge. To cancel, press RETURN switch (2). The default is “ON”. REMARK If the “ECO Gauge Display” is set to “OFF”, the items of “ECO Gauge Display Fuel Target Value”...
Page 123 OPERATION EXPLANATION OF COMPONENTS Using UP switch (2) or DOWN switch (3) to set the value, and press ENTER switch (1). (2) UP switch Increases the target fuel consumption value by 1 ℓ/h. (3) DOWN switch Decreases the target fuel consumption value by 1 ℓ/h. To cancel, press RETURN switch (4).
Page 124 EXPLANATION OF COMPONENTS OPERATION Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the ECO guidance. “OFF” Does not display the ECO guidance. To cancel, press RETURN switch (2). The default is “ON”. REMARK • If “ECO Guidance Display” is turned “OFF”, displays of “ECO Guidance Display at Key OFF”...
Page 125 OPERATION EXPLANATION OF COMPONENTS Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the operational advice on the end screen. “OFF” Does not display the operational advice on the end screen. To cancel, press RETURN switch (2). The default is “ON”. REMARK In the “Operational Advice”...
Page 126 EXPLANATION OF COMPONENTS OPERATION Select “Manual Fan Reverse Mode” on the “Machine Set- ting and Information”, and press ENTER switch (1). REMARK The fan rotation switches from the normal direction to the reverse direction only when all of the following conditions are met.
Page 127 OPERATION EXPLANATION OF COMPONENTS If the condition for reversing the fan is not satisfied, changeover condition waiting pilot lamp (4) lights up in red. Set the engine speed to high idle and perform thecleaning. After finishing the cleaning, set the engine speed to low idle.
Page 128 The default is “Mode A”. When you want other than above settings for the duration and cycle of the automatic fan reverse rotation, consult your Komatsu distributor. REMARK The fan rotation switches from the normal direction to the reverse direction only when all of the following conditions are met.
Page 129 OPERATION EXPLANATION OF COMPONENTS When the set changeover time elapses, fan reverse rota- tion pilot lamp (2) flashes and lights up. If the condition for reversing the fan is not satisfied, changeover condition waiting pilot lamp (3) lights up in red. The fan returns from the reverse rotation to the normal when the set duration for the reverse rotation elapses.
Page 130 EXPLANATION OF COMPONENTS OPERATION Select “Traction Level Selection” on “Machine Setting and Information” menu, then press ENTER switch (1). Select the traction level in accordance with the operating condition, then press ENTER switch (1). “Auto” • Controller judges the operating condition, and set the maximum rim pull automatically.
Page 131 OPERATION EXPLANATION OF COMPONENTS Select “Traction Selection Hold” on “Machine Setting and Information” menu, and press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” The selected traction mode at key OFF is held. “OFF” The traction mode at key OFF is returned to “Auto”. “OFF”...
Page 132 EXPLANATION OF COMPONENTS OPERATION Select “Eco Traveling mode” on “Machine Setting and In- formation” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “OFF” Returns to the normal mode. “ON” Reduces the fuel consumption during traveling at 3rd or 4th while the traction level is set to “Auto”.
Page 133 OPERATION EXPLANATION OF COMPONENTS Select “Reverse Travel Speed Range Limit” on “Machine Setting and Information” menu, and press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “OFF” OFF: Reverse speed range is not limited. “ON” Even when the travel speed range is set in 3rd or 4th, the reverse travel speed range is limited to 2nd or below.
Page 134 EXPLANATION OF COMPONENTS OPERATION Select “Boom Raise Detent Setting” on “Machine Setting and Information” menu, and press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” The boom RAISE detent is enabled. “OFF” The boom RAISE detent is disabled. The default is “ON”.
Page 135 OPERATION EXPLANATION OF COMPONENTS Select “PZ Auto Tilt-in Selection” on “Machine Setting and Information” menu, and press ENTER switch (1). Select the setting of PZ Auto Tilt-in and press ENTER switch (1). “OFF” PZ auto tilt-in function is disabled. “Light” Sets the compensation angle of auto tilt-in to smaller val- “Normal”...
Page 136 EXPLANATION OF COMPONENTS OPERATION TRIP METER The overall travel distance after the previous resetting can be checked by using the “Trip Meter”. You can reset the travel distance according to the following pro- cedure. Select “Trip Meter” on “Machine Setting and Information” menu, then press ENTER switch (1).
Page 137 OPERATION EXPLANATION OF COMPONENTS Select “Auto Idle Stop Timer Setting” on “Machine Setting and Information” menu, and press ENTER switch (1). Select the operating time of the auto idle stop, and press ENTER switch (1). The operating time can be selected from 3 minutes to 60 minutes.
Page 138 For details of the aftertreatment devices regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-124)”. The operation methods and the contents of the display of KDPF regeneration and urea SCR regeneration are common.
Page 139 “Coolant Change” are not set initially. If you want to change the setting for the maintenance interval and the maintenance notice time, consult your Komatsu distrib- utor. When the maintenance time caution lamp (2) is lit on the stand- ard screen, press the menu switch, and the screen automati- cally displays the “Maintenance”...
Page 140 Input the password for restriction of use by using the nu- meric keypad, then press ENTER switch (1). REMARK For the setting, changing, or canceling the password, ask your Komatsu distributor. The screen changes to Maintenance Due Time Reset screen. When ENTER switch (1) is pressed, the following reconfir- mation screen is displayed.
Page 141 OPERATION EXPLANATION OF COMPONENTS MONITOR SETTINGS Each item of “Monitor Setting” menu (F) is to make settings for the machine monitor. REAR VIEW MONITOR SETTING This is used to set the rearview monitor. Select “Rearview Monitor Setting” on the “Monitor Setting” menu screen, and press ENTER switch (1).
Page 142 EXPLANATION OF COMPONENTS OPERATION Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the reference line. “OFF” Hides the reference line. REMARK For the rearview monitor and the reference line, see “HANDLE REAR VIEW MONITOR (3-123)” and “METHOD FOR AD- JUSTING REAR VIEW CAMERA ANGLE (3-167)”.
Page 143 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY SELECTION This is used for the selection of the items to be displayed on L.H. meter display (A) or R.H. meter display (B). Select “Meter Display Selection” on the “Monitor Setting” menu screen, then press ENTER switch (1). SELECT L.H.
Page 144 EXPLANATION OF COMPONENTS OPERATION Select “LH Meter Display Selection” on the “Meter Display Selection” menu, then press ENTER switch (1). Select the items to be displayed, then press ENTER switch (1). The following 3 items can be selected. • “SMR: Service Meter” •...
Page 145 OPERATION EXPLANATION OF COMPONENTS Select “RH Meter Display Selection” on the “Meter Display Selection” menu, then press ENTER switch (1). Select the items to be displayed, then press ENTER switch (1). The following 4 items can be selected. • “FUEL: Average Fuel Consumption” •...
Page 146 EXPLANATION OF COMPONENTS OPERATION Adjust the brightness by using the switch panel. The brightness can be adjusted individually in the day and night modes. (1) Menu switch Brightness is set to default. (2) UP switch Brightness increases. (Moves the indicator to the right by one division.) (3) DOWN switch Brightness decreases.
Page 147 OPERATION EXPLANATION OF COMPONENTS Select “GPS Synchronization” from the “Clock Adjustment” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” Sets the date and time automatically. “OFF” Does not set the date and time automatically. (Can be set manually.) REMARK This setting is held even if the starting switch is turned to OFF...
Page 148 EXPLANATION OF COMPONENTS OPERATION Select “Calendar” from the “Clock Adjustment” menu, then press ENTER switch (4). REMARK As long as “ON” is selected for the “GPS Synchronization”, “Calendar” is not selectable. The “Calendar” screen is displayed. When year display (A) is highlighted in yellow, operate the switches as follows to change year display.
Page 149 OPERATION EXPLANATION OF COMPONENTS When day display (C) is highlighted in yellow, operate the switches as follows to change day display. When it is not necessary to change the day setting, press ENTER switch (4). (1) UP switch Advances calendar one day. (2) DOWN switch Puts calendar back one day.
Page 150 EXPLANATION OF COMPONENTS OPERATION When minute display (E) is highlighted in yellow, operate the switches as follows to change minute display. When it is not necessary to change the minute setting, press ENTER switch (4). (1) UP switch Advances time one minute. (2) DOWN switch Puts time back one minute.
Page 151 OPERATION EXPLANATION OF COMPONENTS Select “Daylight Saving Time” from the “Clock Adjustment” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the time 1 hour forward. “OFF” Returns the time to the original. REMARK Daylight saving time or summer time means moving the clock forward an hour to take advantage of the fact that the sun rises...
Page 152 The “Operator ID” menu is not displayed when the operator identification function is disabled. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi- fication function. WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted, the identified ID is displayed in the column of “Operator ID”...
Page 153 OPERATION EXPLANATION OF COMPONENTS When the starting switch is ON and “SKIP” is selected, “****” is displayed in the column of “Operator ID” on the “Monitor Set- ting” menu screen. Select “Operator ID” on the “Monitor Setting” menu screen, then ENTER switch (1) for 1 second. The “Operator ID Change”...
Page 154 EXPLANATION OF COMPONENTS OPERATION • When you press menu switch (2) on the “Operator ID Change” screen, a message is displayed below and the screen returns to the “Monitor Setting” menu screen. On the “Monitor Setting” menu screen, as the same way when the starting switch is ON and “SKIP”...
Page 155 In this case, the identified ID is not changed. MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this User Message menu (G). When there is any message, message display (1) of the stand- ard screen lights up.
Page 156 EXPLANATION OF COMPONENTS OPERATION REMARK • While message display (1) is lit on the standard screen, when menu switch (2) is pressed, User Message menu screen (G) is displayed automatically. • When the starting switch is turned OFF while there is any unread message, the message is displayed on the end screen, and when the monitor is started next time, the message changes to a read message.
Page 157 NOTICE If the monitor screen is displayed during other operations while the starting switch is at OFF position, there is proba- bly a failure in the equipment, so ask your Komatsu dis- tributor for inspection. 3-91...
Page 158: Switches
EXPLANATION OF COMPONENTS OPERATION SWITCHES g0032100 (1) ECSS switch (2) Front working lamp switch 3-92...
Page 159 OPERATION EXPLANATION OF COMPONENTS (3) Engine shutdown secondary switch (18) Rear heated wire glass switch (4) Speed range selector switch (19) Emergency HST pump drive switch (5) Hazard lamp switch (20) Max. traction switch (6) Horn switch (21) PCS (Proportional Control Switch) (7) Lamp switch (22) Directional selector switch (7) Turn signal lever...
Page 160 EXPLANATION OF COMPONENTS OPERATION CIGARETTE LIGHTER The cigarette lighter is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its origi- nal position after a few seconds, so pull it out to use it. If the cigarette lighter is removed, the socket can be used as an 85 W (24 V x 3.5 A) power supply.
Page 161 OPERATION EXPLANATION OF COMPONENTS HORN SWITCH If you press the horn switch, the horn sounds. TRAVEL SPEED CONTROL DIAL The travel speed control dial is used to freely set the maximum travel speed at the 1st speed range. By turning the dial clockwise, the setting of maximum travel speed becomes higher, and by turning the dial counterclock- wise, the setting becomes lower.
Page 162 If the parking brake was used as a secondary brake when the machine was traveling at high speed, ask your Komatsu distributor for inspection of the parking brake system. The parking brake switch is used to apply the parking brake.
Page 163 OPERATION EXPLANATION OF COMPONENTS REAR WIPER SWITCH When turning the lever (E) of the rear wiper switch, the rear wiper operates. Position (A): Washer fluid is sprayed out. When you release your hand, it returns to position (B). Position (B): (OFF) Wiper is stopped. Position (C): Wiper operates intermittently.
Page 164 Slightly operate the bucket toward DUMP side to release it from the stopper of the boom, and then the effect of the ECSS increases. • To adjust the travel speed of when it is operated or not, consult your Komatsu distributor. 3-98...
Page 165 OPERATION EXPLANATION OF COMPONENTS FRONT WORKING LAMP SWITCH WARNING The working lamps must be turned off when the machine is traveling on a public road. Use the front working lamp switch to light up the front working lamps. Position (A): The working lamps light up. Position (B): The working lamps go out.
Page 166 EXPLANATION OF COMPONENTS OPERATION If you release your hand from the switch, it automatically re- turns to its original position. Position (A): Sets or cancels the stopping position of boom. For the setting and canceling method of the remote positioner, see “REMOTE POSITIONER (3-199)”.
Page 167 OPERATION EXPLANATION OF COMPONENTS The work equipment lock switch is a device used to lock the operation of the work equipment. The work equipment is locked (the pilot lamp lights up) or un- locked (the pilot lamp goes out) each time you press the posi- tion (B) of the switch.
Page 168 EXPLANATION OF COMPONENTS OPERATION REMARK If you release the emergency HST pump drive switch during traveling, the machine may stop abruptly. Release the accelerator pedal, depress the brake pedal, and release the switch after the machine stops. MAX. TRACTION SWITCH With the Max.
Page 169 OPERATION EXPLANATION OF COMPONENTS The current traction control operating state is displayed at the traction level display of the machine monitor. For details of the operating state, see the table. You can select the maximum rim pull when the traction control is turned on from “Auto”, “Level 1”...
Page 170 EXPLANATION OF COMPONENTS OPERATION Traction control operating state Features Traction control Switch position Display on monitor Target material of setting Rim pull Road conditions loading Suitable on the Suitable for heavy Press (A). Large ground not slip- target material. pery. (*1) Can be applied for loading work by au- Automatic ad-...
Page 171 OPERATION EXPLANATION OF COMPONENTS (*3): It is set when the Eco Traveling mode is set to “ON”. To reduce the fuel consumption when traveling at 3rd and 4th speed, we recommend to set the Eco Traveling mode “ON”. For the Eco Traveling mode, see “ECO TRAVELING MODE (3-65)”.
Page 172 OFF position but the engine does not stop. • Use the engine shutdown secondary switch only in an emergency. Contact your Komatsu distributor for repair immediately when there is any abnormality on this switch. • If the engine shutdown secondary switch is set to STOP ENGINE position by mistake while the ma- chine is operating normally, “Engine Shutdown Secondary SW in Operation”...
Page 173: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS Raise cover (1) and open it. There is a switch under the cover. Pull up the switch, and the engine stops. (a) STOP ENGINE: When abnormal (switch is set up) (b) NORMAL: When normal (switch is set down) •...
Page 174 EXPLANATION OF COMPONENTS OPERATION (3) Multifunction mono-lever (5) Brake pedal (4) Accelerator pedal DIRECTIONAL LEVER The directional lever switches the machine travel between the forward and reverse. The engine does not start if the directional lever is not in NEU- TRAL position (N).
Page 175 0 to 162 mm NOTICE Do not operate the steering tilt lock lever repeatedly with an excessive force. The lever can be loosened or its angle can be displaced. In such case, ask your Komatsu distributor for inspection. BRAKE PEDAL WARNING •...
Page 176: Other Components
EXPLANATION OF COMPONENTS OPERATION NOTICE Frequent braking increases the axle oil temperature. As a result, the alarm buzzer may sound and the warning lamp may light up for protection of the brake discs. Observe the following ways of operation to prevent the increase of the axle oil temperature.
Page 177 OPERATION EXPLANATION OF COMPONENTS CAB DOOR HANDLE While the key is not in the lock position, pull right side (1) of the door handle with the right hand, and push left side (2) with the thumb, and the door opens to the full open position, OPEN HANDLE FOR CAB L.H.
Page 178 EXPLANATION OF COMPONENTS OPERATION UNLOCK KNOB FOR SLIDE WINDOW OF CAB Use this to open and close the door window glass up and down. Grip unlock knob (1) to release the lock, then move it to the lower LOCK position and release it. There are 3 stages for LOCK position (A).
Page 179 OPERATION EXPLANATION OF COMPONENTS Pull up door knob (1). Hold door knob (1) and pull it toward the rear of the ma- chine. Remove the guide rail of the door knob from guide pin (2) fixed to the cab and unlock the right side door. Open the right side door wide and go out.
Page 180 EXPLANATION OF COMPONENTS OPERATION NOTICE If the door is closed without holding door knob (1), the plastic part of the door knob hits against guide pin (2) on the cab side and may be broken. Always close the door while holding door knob (1). CAP AND COVER WITH LOCK Use the starting switch key to open and close the locks on the caps and covers.
Page 181 OPERATION EXPLANATION OF COMPONENTS ASHTRAY This is on the right side of the operator's seat. Always extinguish your cigarette before putting it in the ashtray and be sure to close the lid. NOTICE While removing the ashtray, if it is stuck in the console cover and hard to be removed, open lid (A) of ashtray, then hold the ashtray body (B) and twist it to remove.
Page 182 EXPLANATION OF COMPONENTS OPERATION NOTICE • A stereo miniature plug can be connected. • As a power source, use the battery attached to the equipment to connect. If you use an electric power supply installed to the machine, the noise may occur. •...
Page 183 OPERATION EXPLANATION OF COMPONENTS Fuse capacities and circuit names Fuse box A Fuse Name of circuit capacity 20 A Starting switch 10 A Hazard lamp 15 A 30 A Engine control 10 A Monitor display 15 A Radio 10 A Auxiliary power supply 10 A L.H. headlamp 10 A R.H.
Page 184 EXPLANATION OF COMPONENTS OPERATION Fuse box C Fuse Name of circuit capacity 20 A Smart sensor 10 A Smart sensor 10 A DEF heater 20 A DEF heater SLOW-BLOW FUSE NOTICE When replacing the slow-blow fuse, be sure to turn the starting switch to OFF position and, after con- firming that the system operating lamp is not lit, set the battery disconnect switch key to OFF position.
Page 185 OPERATION EXPLANATION OF COMPONENTS This is a device used to lock the front and rear frames to pre- vent the machine from being articulated during the mainte- nance or transporting the machine. (L) LOCK position It is used for maintenance and transportation The front frame and the rear frame are locked so that the ma- chine body is not articulated.
Page 186 EXPLANATION OF COMPONENTS OPERATION Fold the handle (4) of towing pin (1) to lock. When removing it, perform the procedure in the reverse or- der. BATTERY DISCONNECT SWITCH CAUTION • Do not operate the battery disconnect switch while the engine is running. The large current generated by the alternator may burn the electric parts and cause a fire.
Page 187 OPERATION EXPLANATION OF COMPONENTS The battery disconnect switch is used to cut out the electricity from the battery. Open the cover (1) of the battery box on the rear right of the machine, raise the rubber cover (2), and battery disconnect switch (3) is seen.
Page 188 • After the starting switch has been turned off, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. • While DEF system devices are operating, the system operating lamp lights up to return DEF to the tank.
Page 189 OPERATION EXPLANATION OF COMPONENTS HANDLE REAR VIEW MONITOR WARNING • Never operate any of the switches while traveling. If you do so, there is a danger that you may make an error in the machine operation, or neglect to watch the travel path ahead for safety, and as a re- sult cause a serious personal injury or death.
Page 190 EXPLANATION OF COMPONENTS OPERATION HANDLE Komatsu Diesel Particulate Filter (KDPF) CAUTION • Exhaust gas temperature may increase during the aftertreatment devices regeneration and the high temperature may last after the completion of regeneration. Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt.
Page 191 OPERATION EXPLANATION OF COMPONENTS The KDPF regeneration is performed automatically. However, the accumulated soot may not be burnt sufficiently and the fil- tering function may not be improved under certain operating conditions. In that case, KDPF soot accumulation caution lamp (2) lights up.
Page 192 Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may cause failure.
Page 193 OPERATION EXPLANATION OF COMPONENTS When the degree of emergency is high • KDPF soot accumulation caution lamp (2) lights up in red and the action level “L03” lights up in red (4). • If the machine is stopped completely, the screen changes to the “Aftertreatment Devices Regeneration”...
Page 194 EXPLANATION OF COMPONENTS OPERATION Set the parking brake switch to ON position (A) and apply the parking brake. Press the menu switch to display “Aftertreatment Devices Regeneration” screen. Select the manual stationary regeneration, check again safety of the surrounding area and make sure the area is free from irrelevant people or combustible material, then press ENTER switch.
Page 195 OPERATION EXPLANATION OF COMPONENTS REMARK • The explanation of the manual stationary regeneration is displayed in 3 parts on the monitor panel. When ENTER switch is pressed, the regeneration can be started immediately, regardless of which part is dis- played. When RETURN switch is pressed, the display returns to the standard screen.
Page 196 EXPLANATION OF COMPONENTS OPERATION REMARK • The progress of the manual stationary regeneration performed when soot is accumulated can be checked by the number of lighting lamps of soot accumulation level (2). The manual stationary regeneration starts at soot accumulation level “4” or higher and finishes when all the level lamps go out.
Page 197 OPERATION EXPLANATION OF COMPONENTS Operate the menu switch to select “Aftertreatment Devices Regeneration” menu (C) and display “Aftertreatment Devi- ces Regeneration” screen. Select Regeneration Disable and press ENTER switch. The regeneration function is disabled and the regeneration is not performed. REMARK •...
Page 198 The regeneration disable setting is also canceled by turn- ing the starting switch to OFF position to stop the engine. KOMATSU CLOSED CRANKCASE VENTILATION (KCCV) KCCV is a device to clean the gas discharged from the engine crankcase and return it to the engine air intake system.
Page 199 Urea SCR systems by utiliz- ing visible and audible alerts , and engine power derate in addition. Alerts in Inducement of the Komatsu Urea SCR System progresses step by step starting from visual indications on the machine monitor and audible sounds to engine power derate to avoid getting into unsafe conditions.
Page 200 In addition, it may cause fail- ures in the engine system. If DEF out of the standard is filled or used by mistake, contact your Komatsu dis- tributor. About the operation of Urea SCR system The Urea SCR System automatically starts operating as soon as the engine is started.
Page 201 OPERATION EXPLANATION OF COMPONENTS and injection while heating continues. Once the ambient temperature rises above a temperature where DEF system becomes functional, it resumes operation automatically. Short duration of white plume given off from the tail pipe may be visible at and shortly after engine start-up in cold weather, but this is not malfunction.
Page 202 EXPLANATION OF COMPONENTS OPERATION Inducement status (4): “1 DEF low level warning appears.” Add DEF to the DEF tank immediately. • Continuous Warning: The audible alert sounds in “Intermittent alarm”. 2 gradations of the DEF level gauge light up in the red range.
Page 203 “L04 (Severe Inducement)” is displayed. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Infor- mation” screen of the user menu.
Page 204 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen displays remaining time to the next Inducement status in the column (5), and information on the Urea SCR System condition (3), and the current status of In- ducement (4). • Warning: No audible alert. The DEF system caution lamp (1) lights up in yellow.
Page 205 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Low level Inducement”.
Page 206 Once the system advances to “Severe Inducement”, the engine power will be further derated. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 207 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen message (5): “1 Please inspect and maintain SCR system.” Engine power is derated. Move the machine to the safe place and contact your Ko- matsu Distributor. If operation continues for 5 hour after “Warning” started without taking any actions instructed by the Action Level table, Inducement advances to “Continuous Warning”.
Page 208 Once the system advances to “Severe Inducement”, the engine power will be further derated. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 209 OPERATION EXPLANATION OF COMPONENTS Perform the following procedure. Press the menu switch to display the “SCR Information” screen of the user menu. After a lapse of 3 seconds to stop the machine, “SCR Informa- tion” screen is displayed. “SCR Information” screen displays remaining time to the next Inducement status in the column (6), and information on the Urea SCR System condition (4), and the current status of In- ducement (5).
Page 210 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen message (5): “2 Without treat- ment, engine power will be derated.” Move the machine to the safe place and contact your Ko- matsu Distributor. The duration time of “Continuous Warning” is 5 hour. The remaining time (Hours and Minutes) to “Low level Induce- ment”...
Page 211 Restoration from Inducement” in this manual. If Inducement advances to “Severe Inducement” and it be- comes necessary to restore engine power, use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor. Temporary Restoration from Inducement Temporary Restoration from Inducement is the one of the Inducement strategies allowed to be included in Urea SCR systems.
Page 212 EXPLANATION OF COMPONENTS OPERATION Press the enter switch (2) while the pop-up menu screen B is displayed. The “Engine power Recovery” window will be displayed. If the enter switch (2) is not pressed for 30 seconds, “Standard Screen” will be displayed, and start again by pressing the menu switch (1).
Page 213 Inducement. If this occurs, utilize “Temporary Restoration from Inducement” and move the machine to a safe place, and con- tact your Komatsu distributor. The maximum duration of power restoration is 30 minutes and 3 operations are allowed.
Page 214 It can be useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma- chine information for supply of service to the customers, improvement of our products and service, etc.
Page 215: Machine Operations And Controls
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. If the machine is inclining, make it level before checking.
Page 216 MACHINE OPERATIONS AND CONTROLS OPERATION 11. Check the HST piping, transfer case, axle, hydraulic tank, hoses, and joints for oil leakage. Check for oil leakage. If any problem is found, repair the place where the oil is leaking. 12. Check brake line for oil leakage. Check for leakage of oil or damage to the hoses and tubes.
Page 217 If any problem is found, replace the part. 23. Check the rearview monitor. Check the rearview monitor for problem. If it is failed, ask your Komatsu distributor for repair. METHOD FOR CHECKING BEFORE STARTING Always check the items in this section before starting the engine each day.
Page 218 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDI- MENT WARNING • Immediately after the engine is stopped, all of parts are still very hot. Avoid draining water or re- moving the transparent cup. Wait for all parts to cool down before starting the work. •...
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS Check for water and sediment. It is possible to judge the water level and amount of sedi- ment by looking through transparent cup (4). NOTICE • If the water accumulated in transparent cup (4) freezes, the water separator caution lamp (6) may not light up.
Page 220 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT WARNING • Do not open the radiator cap unless it is necessary. When checking the coolant level, check it with the reservoir tank when the engine is cold. •...
Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS Open the engine side cover (1) on the right side of the ma- chine. Pull out the dipstick (G) and wipe the oil off with a cloth. Fully insert the dipstick (G) into the dipstick pipe, then pull it out.
Page 222 • If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause of it and to perform the repair. • Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap with water to clear the vent hole.
Page 223 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the starting switch to ON position (B). Check the fuel level with fuel gauge (G). After checking, return the starting switch to OFF position (A). Open the rear grill (1), and add fuel through the filler port (F) to fill up the fuel tank if the fuel level is low.
Page 224 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the audible alert sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and for inspection. DEF injector and/or DEF pump may need to be replaced.
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS Set the frame lock bar (2) to LOCK position (L). Open up cover (3) at the right side of the machine, clean blue DEF tank filler cap (4) and surrounding area. Turn the cap (4) counterclockwise. The caps of DEF tanks are blue, as required by emission regulations.
Page 226 If the fluid does not spout out normally, clean the washer nozzle hole with a fine wire such as a safety pin. • If the condition does not become normal, ask your Komatsu distributor to perform inspection and repair. METHOD FOR CHECKING WIPER FUNCTION Operate the wiper in the “Intermittent”, “Low”, and “High”...
Page 227 METHOD FOR CHECKING HORN Operate the horn switch and check that the horn sounds. If there is any abnormality, ask your KOMATSU distributor for testing and repair. METHOD FOR CHECKING DEFROSTER FUNCTION • Operate the air conditioner and check that the air flows out of the vents properly onto the front glass.
Page 228 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING SEAT UNIT IN FORE-AND-AFT DIRECTION Operate the lever upward, set the seat to the desired position, and then release the lever. Fore-and-aft adjustment: 152.4 mm (12.7 mm x 12 stages) METHOD FOR RECLINING SEAT NOTICE If the backrest is reclined too far, the headrest or seat belt anchor (when the 3-point seat belt (optional) is installed) may contact the rear window glass, so move it to a position where it does not contact the window glass.
Page 229 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE Do not operate the switch continuously for 1 minute or longer. Doing so can damage the air compres- sor. The seat height is adjusted pneumatically and in stepless. Adjust the suspension strength and seat height by pressing the switch.
Page 230 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING HEADREST IN VERTICAL DIRECTION Move the headrest up or down to the desired height. Adjustment amount: 127 mm METHOD FOR ADJUSTING ARMREST ANGLE Turn the knob to adjust the armrest angle. Amount of adjustment: 35 ° (Forward tilt 12 °, backward tilt 23 °) REMARK You can flip up the armrest.
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS • To increase the damping force, direct the knob toward bot- tom side (A) of the seat. • To decrease the damping force, direct the knob toward top (B) of the seat. Adjustment amount 1st stage: at position (c) 2nd stage: at position (d) 3rd stage: at position (e) 4th stage: at position (f)
Page 232 Tighten the mirror mounting bolts securely to prevent the mirrors from coming off due to loosening of the bolt. Tightening torque of mirrors (A) and (B): 2.0 to 2.5 Nm {0.2 to 0.25 kgm} • If the torque cannot be controlled, ask your Komatsu distributor for adjustment. 3-166...
Page 233 When adjusting the angle of the camera, prepare a scaffold first in order to provide a safe working platform. If you try to work standing on the counterweight, there is a danger of serious injury or death due to falling off from the machine. • Install only the Komatsu genuine camera. 3-167...
Page 234 MACHINE OPERATIONS AND CONTROLS OPERATION Adjusting rear view camera angle Adjust the angle of the rear view camera so that people within 1 m away from the machine's rear part (W) is displayed in the monitor at the operator's seat. If the image on the monitor is not aligned correctly, adjust mounting angle (A) of the rear view camera.
Page 235 OPERATION MACHINE OPERATIONS AND CONTROLS Loosen mounting bolts (1) (3 places) and adjust angle (A). REMARK A part of the machine is shown on the monitor screen. After adjusting, tighten bolts (1) (3 places). 3-169...
Page 236 (D) matches to position (B) that is 1.5 m away from the rear end of the machine. When the reference line is abnormal, change its setting to Non- display and contact your Komatsu distributor. METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING •...
Page 237 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR FASTENING SEAT BELT Sit in the seat and depress the brake pedal fully. Under this condition, adjust the seat so that your back is fitted to the backrest. Sit on the seat, pull the belt on right side, then insert tongue (1) into buckle (2) until a click is heard.
Page 238 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING When starting the engine, check that the work equipment is securely locked (the pilot lamp in the switch is lit). If the multifunction mono-lever is touched by accident when starting the engine, the work equipment may move unexpectedly, and this may lead to a serious injury or death.
Page 239 OPERATION MACHINE OPERATIONS AND CONTROLS Check that the directional lever (2) is in NEUTRAL position (N). REMARK The engine can be started only when the directional lever is in NEUTRAL position (N). When the directional selector switch actuation switch (3) is in ON position (A), check that the directional selector switch (4) is in NEUTRAL position (N).
Page 240: Method For Starting Engine
The engine tachometer swings once. If the monitor does not light up, there may be a failure or wire breakage. Ask your Komatsu distributor for inspection. Check that the work equipment is locked (the pilot lamp in the switch (6) is lit).
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key in starting switch (1) to ON position (B). When the ambient temperature is low, preheating pilot lamp (2) lights up and automatic preheating is performed. Keep the starting switch key (1) at ON position until pre- heating pilot lamp (2) goes out.
Page 242 MACHINE OPERATIONS AND CONTROLS OPERATION START IN COLD WEATHER WARNING • Start the engine only while sitting on the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may cause a fire or serious personal injury or death. •...
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS After preheating pilot lamp (2) goes out, turn starting switch key (1) to START position (C). Keep the key in starting switch (1) at position (C) to keep running the starting motor until the engine starts. The starting motor keeps running to start the engine.
Page 244: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 245 Drive the machine forward and in reverse slowly on a level ground with no obstacles around and check the brake performance. If any problem is found in operation of the brake, ask your Komatsu distributor for adjustment. METHOD FOR CHECKING CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR Depress the brake pedal fully and check that the pedal is not too close to the floor.
Page 246 MACHINE OPERATIONS AND CONTROLS OPERATION Depress the accelerator pedal (1) lightly and run the en- gine at a medium speed for approximately 5 minutes with no load. Only in cold weather, perform the following operation to warm up the hydraulic oil. Check that the engine rotation is smooth, then cancel the work equipment lock (turn off the pilot lamp in the switch) with the work equipment lock switch after the warm-up op-...
Page 247: Method For Stopping Engine
(3) and HST oil temperature gauge (4) indicate the green range. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distribu- tor. REMARK The cooling fan speed varies according to the following conditions, but it is not abnormal.
Page 248: Method For Starting Machine (Travel Forward And Reverse, And Shifting Gear) And Stopping Machine
MACHINE OPERATIONS AND CONTROLS OPERATION Turn the key of starting switch (1) to OFF position (A), and stop the engine. Remove the key from starting switch (1). REMARK • After the engine is stopped, DEF in DEF injector and pump is automatically purged and returned to the tank to prevent malfunction of the devices caused by freez- ing of DEF or deposition of urea.
Page 249 OPERATION MACHINE OPERATIONS AND CONTROLS Check that the caution lamp (1) is not lit. Check that the multifunction mono-lever (2) is in “HOLD” position. Cancel the work equipment lock (the pilot lamp in the switch goes out) with the work equipment lock switch (3). Operate the multifunction mono-lever (2) to set the work equipment to the travel posture as shown in the figure.
Page 250 Position (R): REVERSE Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does not sound, ask your Komatsu dis- tributor for repair. REMARK You can also use the directional selector switch (7) to set the travel direction to FORWARD, NEUTRAL, and RE- VERSE.
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS Release the R.H. brake pedal (4), then depress the accel- erator pedal (9) to move off. METHOD FOR SELECTING SPEED RANGE WARNING Avoid an abrupt shifting of the speed range while traveling at high speed. Reduce the speed by releas- ing the accelerator pedal always before selecting the speed range.
Page 252 Position (R): REVERSE Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does not sound, ask your Komatsu distribu- tor for repair. REMARK If you operate the directional lever slowly or stop it at midway between the lever positions, the centralized warning lamp may light up and the alarm buzzer may sound.
Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS Directional selection by switch operation WARNING When shifting the directional lever (1) to FORWARD (F) or REVERSE (R) position while the directional selector switch actuation switch (3) is in ON position, the machine travels forward or in reverse in accordance with the directional lever (1) regardless of the position of the directional selec- tor switch (2).
Page 254 MACHINE OPERATIONS AND CONTROLS OPERATION Set the directional selector switch (2) to FORWARD (F) or REVERSE (R) position. REMARK When shifting the directional lever (1) to FORWARD (F) or REVERSE (R) position while the directional se- lector switch actuation switch (3) is in ON position, the machine travels forward or in reverse in accordance with the directional lever (1) regardless of the position of the directional selector switch (2).
Page 255 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE Never use the parking brake switch to brake the machine when the machine is traveling except in an emergency. Apply the parking brake after the machine is stopped. Release the accelerator pedal (1), then depress the brake pedal (2) to stop the machine.
Page 256: Method For Steering Machine
Check that the play (a) of steering wheel is 60 mm or less, and that the operation of steering wheel is nor- mal. If any problem is found, ask your Komatsu dis- tributor for inspection. 3-190...
Page 257: Method For Operating Work Equipment
OPERATION MACHINE OPERATIONS AND CONTROLS HANDLE SECONDARY STEERING SYSTEM CAUTION • Do not actuate the secondary steering except in trou- ble or checking the function. • When using the secondary steering, limit the travel speed to 5 km/h or less. The secondary steering pilot lamp (green) (1) lights up to in- form the operator that the secondary steering system has been actuated.
Page 258 MACHINE OPERATIONS AND CONTROLS OPERATION The multifunction mono-lever (1) is used to operate the boom and bucket in the following manners. METHOD FOR OPERATING BOOM The multifunction mono-lever is used to operate the boom. NOTICE Do not use “FLOAT” position when lowering the bucket. Use “FLOAT”...
Page 259: Precautions For Operation
If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine. NOTICE If the parking brake was used as a secondary brake, ask your Komatsu distributor to inspect the park- ing brake system for any trouble.
Page 260: Recommended Applications
• The most suitable tire pressure and travel speed differ according to the tire type and condition of the travel surface. Contact your Komatsu distributor or tire dealer. • The following shows the appropriate tire inflation pressure and travel speed when the machine is equipped with the standard tires (20.5R25☆) and runs on the paved surface.
Page 261 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE If the tires slip, the tire life will be reduced, so operate the machine avoiding tire slippage. LOAD STOCK PILES When loading the stockpile, drive the machine forward as shown below to scoop them. Reduce the load by slightly raising the bucket if tire starts slipping due to the heavy load.
Page 262 MACHINE OPERATIONS AND CONTROLS OPERATION Set the cutting edge slightly downward from the horizontal. Drive the machine forward and dig soil and sand bit by bit as if they are ripped off by tilting the multifunction mono- lever slightly forward. Keep on driving the machine forward while adjusting the digging depth by using the multifunction mono-lever.
Page 263 If this is not done, the tires will be damaged. Consult your Komatsu distributor or tire dealer. The load and carry method for wheel loaders consists of a cy- cle of scooping → hauling → loading (into a hopper, glory hole etc.).
Page 264 MACHINE OPERATIONS AND CONTROLS OPERATION CROSS DRIVE LOADING When performing digging, set the wheel loader at a right angle to the target stock pile. After digging in and scooping up the load, drive the machine straight back in reverse, then bring the dump truck in between the stock pile and the wheel loader.
Page 265: Method For Adjusting Work Equipment Posture
OPERATION MACHINE OPERATIONS AND CONTROLS The fuel efficiency and the work efficiency are better in the traction mode “Auto” than in traction mode “MAX”. METHOD FOR ADJUSTING WORK EQUIPMENT POSTURE WARNING • Place the machine on a level ground and move parking brake switch from OFF position (B) to ON position (A) with brake pedal depressed to apply parking brake se- curely, and then confirm that the machine is stopped...
Page 266 MACHINE OPERATIONS AND CONTROLS OPERATION Return the multifunction mono-lever to “HOLD” position (b). Press (A) of the remote positioner switch (1). A “beep” sounds and the position is set. Operation checkup procedure • Lower the boom once, operate the multifunction mono-lever to the position (RAISE detent position) where the lever is further pulled than “RAISE”...
Page 267 OPERATION MACHINE OPERATIONS AND CONTROLS Return the multifunction mono-lever to “HOLD” position (b). Hold down (A) of the remote positioner switch (1) for 1 second or longer. A “beep” sounds and the stop position is reset. If it is reset, when the multifunction mono-lever is set to the position where it is pulled further than the “RAISE”...
Page 268 MACHINE OPERATIONS AND CONTROLS OPERATION If the attachment selector switch is equipped, turn the switch to the bucket position (A). Loosen the nut (1), and adjust the position of proximity switch (3) so that the rear end (A) of the bar (2) is matched to the center of sensory surface (B) of the proximity switch (3).
Page 269 OPERATION MACHINE OPERATIONS AND CONTROLS Adjust the range "c" with nut (1) so that the tip (C) of pro- tector (5) protrudes 0.5 to 1.0 mm from the sensory sur- face (B) of all proximity switches (3). Adjust the auto tilt-in proximity switch (6) so that the dis- tance (e) between centers of the bucket proximity switch (3) and the auto tilt-in proximity switch (6) becomes 145.5 to 149.5 mm.
Page 270: Method For Parking Machine
MACHINE OPERATIONS AND CONTROLS OPERATION When the load is likely spilled out toward TILT side If the load tends to be spilled to TILT side while raising the boom to the maximum height on uphill, set the PZ auto tilt-in setting to “Light”.
Page 271 OPERATION MACHINE OPERATIONS AND CONTROLS Release the accelerator pedal (1), then depress the brake pedal (2) to stop the machine. The machine stops. Set the directional lever (3) in NEUTRAL position (N). Set the parking brake switch (4) to ON position (A) to apply the parking brake.
Page 272: Method For Checking After Finishing Work
If oil or coolant leakage or any abnormality is detected, repair it. Check DEF tank, pump, injector, hose, and joint for leakage. If any abnormality is found, ask your Komatsu distributor for repair. Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
Page 273 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP PROCEDURES FOR OPENING FUEL FILLER PORT CAP Insert the starting switch key into the key slot. Turn the starting switch key to “OPEN” position (A), and then align the key slot with match mark (1) of the cap.
Page 274 MACHINE OPERATIONS AND CONTROLS OPERATION Insert the starting switch key into the key slot. Turn the starting switch key to “OPEN” position (A), and then align the key slot with the match mark (3) of the cap. Position (A) OPEN Position (B) LOCK Turn the oil filler cap slowly to unlock it.
Page 275: Handle Tire
(5) Bead (6) Inner liner (7) Cord Contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. TIRE PRESSURE Check the tire inflation pressure before driving, when the tires are cool.
Page 276 When traveling continuously in load-and-carry operation, choose the appropriate tires to match the operating conditions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged. Consult your Komatsu distributor or tire dealer. 3-210...
Page 277: Handle Air Conditioner
To allow the air conditioner to show its full performance, have inspection and maintenance performed peri- odically. When adding refrigerant or performing other maintenance, special tools and instruments are nee- ded, so ask your Komatsu distributor to perform inspection and maintenance. •...
Page 278: Explanation Of Air Conditioner Equipment
HANDLE AIR CONDITIONER OPERATION EXPLANATION OF AIR CONDITIONER EQUIPMENT (1) OFF switch (6) FRESH/RECIRC air selector switch (2) Auto switch (7) Vent selector switch (3) Air conditioner switch (8) Defroster switch (4) Fan switch (9) Display monitor (5) Temperature control switch Air conditioner monitor (A) Air flow bar (E) Vent display...
Page 279 OPERATION HANDLE AIR CONDITIONER • During auto operation, the air flow is automatically adjusted. The set position of the air flow is indicated on the display monitor. Monitor display Air flow Air flow “LOW” Air flow “MEDIUM 1” Air flow “MEDIUM 2” Air flow “MEDIUM 3”...
Page 280 HANDLE AIR CONDITIONER OPERATION VENT SELECTOR SWITCH In the manual operation, use the vent selector switch to select the vents. • There are 4 modes of vents: FACE, FACE/FOOT, FOOT, and FOOT/DEF. (DEF is selected only when the defroster switch is pressed.) •...
Page 281 OPERATION HANDLE AIR CONDITIONER AUTO SWITCH Use auto switch for automatic selection of the air flow and vents according to the set temperature. This switch is also used as the main switch of the air condition- • When AUTO switch is pressed, AUTO on the display moni- tor lights up to indicate that the air conditioner is in the au- tomatic mode.
Page 282 HANDLE AIR CONDITIONER OPERATION DISPLAY MONITOR The display monitor displays the state of air flow (A), operation of air conditioner (B), set temperature (C), FRESH/RECIRC air (D), vents (E), automatic operation (F), and defroster (G). AIR CONDITIONER SWITCH Use the air conditioner switch to start and stop the cooling, heating, or drying function.
Page 283: Method For Operating Air Conditioner
OPERATION HANDLE AIR CONDITIONER DEFROSTER SWITCH The defroster switch is used to set the vents in the defroster mode. • Use this mode to clear the front glass mist, etc. • When the defroster switch is pressed during automatic op- eration, AUTO on the air conditioner monitor goes out and the defroster mark is displayed.
Page 284 HANDLE AIR CONDITIONER OPERATION Press (A) or (B) of the temperature control switch to set to the desired temperature. The air flow and combination of the vents are automatically selected according to the set temperature, and the air con- ditioner is operated automatically to provide the set tem- perature.
Page 285 OPERATION HANDLE AIR CONDITIONER Turn the air conditioner switch ON. At this time, the air conditioner operation mark lights up on the display monitor. Press (A) or (B) of the temperature control switch to adjust the temperature in the cab. REMARK The air temperature is so adjusted that the temperature in the cab becomes the set temperature when the set tem-...
Page 286 HANDLE AIR CONDITIONER OPERATION METHOD FOR OPERATING DEFROSTER Frost adhered to the outside of the window glass can be removed by defroster operation. Press the defroster switch to set the vents in DEF mode. Press FRESH/RECIRC air selector switch and set it to RE- CIRC mode.
Page 287: Transportation
OPERATION TRANSPORTATION TRANSPORTATION TRANSPORTATION PROCEDURE When transporting the machine, choose the transportation method in reference to the weight and dimensions of machine. Note that the “SPECIFICATIONS” (weight and dimensions) vary depending on the type of tire and bucket. LOADING AND UNLOADING WITH TRAILER WARNING •...
Page 288 TRANSPORTATION OPERATION Press the work equipment lock switch (1) and lock the work equipment (the pilot lamp in the switch is lit). Move the parking brake switch (3) from OFF position (B) to ON position (A), with the brake pedal (2) depressed, to ap- ply the parking brake securely.
Page 289 OPERATION TRANSPORTATION Securing position Fixing angle (A) : 69 ° (B) : 59 ° (C) : 33 ° (D) : 46 ° Expected trailer width (E) : 2990 mm 3-223...
Page 290 TRANSPORTATION OPERATION The fixed load per 1 piece Front frame: 98000 N {9990 kg} Rear frame: 118000 N {12030 kg} REMARK When putting the chains or wire ropes to the tie down hole, you may open the engine side cover (4) to perform the work. PROCEDURES FOR UNLOADING MACHINE Perform unloading of the machine on a firm, level ground.
Page 291: Method For Lifting Machine
This method of lifting applies to the standard specification machine. The method of lifting differs depending on the attachments and options installed. For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor. For the weight, see “SPECIFICATIONS (5-2)”.
Page 292 TRANSPORTATION OPERATION Start the engine. Set the machine horizontally and set the work equipment in the travel posture. See “METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE, AND SHIFTING GEAR) AND STOPPING MACHINE (3-182)”. (A): 30 cm Check that the multifunction mono-lever is in “HOLD” posi- tion.
Page 293: Cold Weather Operation
If DEF or the machine equipped with DEF system cannot be stored when the outside temperature is lower than –11 °C, DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF, and keep it in the condition free from freezing.
Page 294: Precautions After Daily Work Completion
Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “RECOM- MENDED FUEL, COOLANT, AND LUBRICANT (7-4)”. If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by repeated freeze, ask your Komatsu distributor to inspect. 3-228...
Page 295: Precautions For Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, perform the following items before using it. •...
Page 296 If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement. Dispose of drained DEF according to the local regulations and rules.
Page 297: Troubles And Actions
For the allowable towing capacity for this machine, see “SPECIFICATIONS (5-2)”. • For the procedure for towing a disabled machine, consult your Komatsu distributor. This machine must not be towed except in emergencies. However, if it is avoidable to tow the machine, take the following precautions.
Page 298 TROUBLES AND ACTIONS OPERATION • Keep the angle of the towing rope as small as possible. Keep the angle between the center lines of the 2 machines to within 30 °. • Usually, use a towing machine of the same class as the machine being towed. Check that both towing ma- chine and towed machine have ample braking power, and rim pull to allow them to control both machines on slopes or on the tow road.
Page 299 OPERATION TROUBLES AND ACTIONS Loosen the plug (1) under the HST pump until it touches the stopper (2). By doing so, the HST pump circuit is bypassed and the travel is enabled. Set the parking brake switch (3) to OFF position (B) to re- lease the parking brake.
Page 300 If it is necessary to move the machine to a safe place urgently, move the machine with the emergency HST pump drive switch. NOTICE If there should be a failure in the electrical system, and the machine does not move, ask your Komatsu distributor. 3-234...
Page 301: Precautions For Discharged Battery
OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch and battery discon- nect switch keys to OFF positions.
Page 302 TROUBLES AND ACTIONS OPERATION REMARK The batteries are on both sides at the rear of the machine. The ground wire side battery is on the right side of the machine. PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, it is dangerous that the battery may explode.
Page 303 OPERATION TROUBLES AND ACTIONS START ENGINE WITH JUMPER CABLES WARNING • Never connect the positive (+) and negative (-) termi- nals when connecting the cables. • Wear the protective eyeglasses and rubber gloves al- ways when starting the engine by using the jumper ca- ble.
Page 304: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 305 PHENOMENA AND ACTIONS FOR CHASSIS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy Parking brake is applied.
Page 306 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Axle Add oil to the specified level by refer- Lack of oil ring to WHEN REQUIRED. Noise is generated. Improper oil is used (for machines Change the oil to the appropriate oil. with limited slip differential) Brake Disc has worn to wear limit.
Page 307 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 308 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Indicator of engine coolant tempera- Defective thermostat Replace thermostat. (*) ture gauge does not rise up to the Replace coolant temperature gauge. green range Defective coolant temperature gauge Defective monitor Replace. (*) Starting motor turns but engine does Add fuel.
Page 309 REMARK If no point of contact telephone number is registered, no tele- phone number is displayed. Ask your Komatsu distributor for the telephone number regis- tration if necessary. 3-243...
Page 311: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 312: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 313: Precautions For Scr Assembly
MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR SCR ASSEMBLY Be careful for the high temperature parts when performing inspection and maintenance. Even after the engine stops the parts around SCR device may be at high temperature. DUSTY JOBSITES When working at dusty jobsites, observe the following. •...
Page 314: Fuel And Lubricants To Match The Ambient Temperature
PRECAUTIONS FOR MAINTENANCE MAINTENANCE • Check if the inspected and serviced area is normally operated. FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE It is necessary to select fuel or lubricant according to the ambient temperature. For detail, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)”. CLOSE ENGINE SIDE COVER SECURELY When closing the engine side cover after inspection and maintenance, lock it securely with the catcher.
Page 315: Outline Of Maintenance
• When using commercially available oil, it may be necessary to reduce the oil change interval. We recom- mend that you use the Komatsu oil clinic to check the characteristics of the oil in detail. NOTICE Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu...
Page 316 (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 317 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 318 • When replacing oil filters, check if any metal particles are attached to the old filters. If any metal particles are found, consult your Komatsu distributor. • Do not open packages of spare filters until just before they are to be used.
Page 319: Handle Electrical Components
Komatsu recommends installing electric components specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. • When working at the seashore, keep the electrical component clean to prevent corrosion.
Page 320: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 321 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Taper seal Tightening torque Nominal Thread size “a” Width across flats Target value Allowable range No. of hose (mm) “b” (mm) Nm kgm Nm kgm 34 to 63 3.5 to 6.5 59 to 98 6.0 to 10.0 10.5 84 to 132...
Page 322: Maintenance Schedule
MAINTENANCE SCHEDULE MAINTENANCE MAINTENANCE SCHEDULE If the currently used diesel fuel which does not include the bio-fuel is changed to the one mixed with the bio-fuel, the replacement interval of the fuel filter is changed as well. See “MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED (4-13)”.
Page 323: Maintenance Interval When Diesel Fuel Mixed With Bio-Fuel Is Used
MAINTENANCE MAINTENANCE SCHEDULE TABLE METHOD FOR CHECKING AND REPLACING ALTERNATOR BELT............. 4-64 EVERY 2000 HOURS MAINTENANCE ......................4-64 METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER... 4-64 METHOD FOR REPLACING HYDRAULIC OIL FILTER CARTRIDGE............ 4-67 METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ..........4-68 METHOD FOR CHANGING OIL IN AXLE CASE ..................
Page 324 MAINTENANCE SCHEDULE TABLE MAINTENANCE Maintenance interval after the diesel fuel has been changed to the diesel fuel mixed with bio-fuel Operating hours of the machine Service meter Every 500 hours Every 1000 hours 250 hours 500 hours Within 500 After 500 op- Within 500 After 500 op- When...
Page 325: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) Until first 100 hours operation, perform the following maintenance every 10 hours. • Lubrication of work equipment • Lubrication of steering cylinder pin For details of the method of replacement or maintenance, see EVERY 100 HOURS MAINTENANCE and EV- ERY 250 HOURS MAINTENANCE.
Page 326 MAINTENANCE PROCEDURE MAINTENANCE Open the engine side cover (1) on the right side of the ma- chine. Clean the element when the yellow piston shown in the dust indicator (2) display of the air cleaner enters the red (7.5 kPa, {0.076 kg/cm }) position.
Page 327 MAINTENANCE MAINTENANCE PROCEDURE Clean the inside of the air cleaner body, cover (3) and va- cuator valve (6). NOTICE Do not clean and reuse the inner element. When replacing the outer element, replace the inner element with a new one at the same time. When cleaning the element, do not tap it or hit it against something.
Page 328 MAINTENANCE PROCEDURE MAINTENANCE 10. Install the cover (3) and fix it with clip (2). 11. Push the button of dust indicator. The yellow piston returns. 12. Close the engine side cover (1) on the right side of the ma- chine. Even though the outer element has not been cleaned up to 6 times, if the yellow piston of dust indicator laps over the red zone (7.5 kPa, {0.076 kg/cm }) soon after the cleaning, replace both the inner and outer elements.
Page 329 MAINTENANCE MAINTENANCE PROCEDURE NOTICE Be sure to install the air cleaner element facing in the cor- rect direction. Install it so that the bottoms (A) and (B) of the air cleaner element (face where no hole is drilled) come to the cover (3) end.
Page 330: Method For Cleaning Inside Of Cooling System
The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 331 When handling the cooling water containing coolant that has been drained during changing the coolant or repairing the radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 332 MAINTENANCE PROCEDURE MAINTENANCE Open the drain valve (4) at the bottom of the radiator and drain the coolant. Tighten the drain valve (4) and add tap water. Add water until it fills the radiator. Start the engine. 10. Depress the accelerator pedal (5) lightly and run the en- gine at a medium speed for approximately 5 minutes with no load.
Page 333 MAINTENANCE MAINTENANCE PROCEDURE WARNING If you turn the steering wheel and stop turning it at certain position while the oil temperature is low, a time lag may result until the machine stops after the turning operation. In such case, set the frame lock bar to LOCK position (L) for safety and perform the warm-up operation in a large place.
Page 334: Method For Checking Oil Level In Transfer Case And Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE 19. Drain the coolant in reservoir tank (9). 20. Clean the inside of reservoir tank (9). 21. Add the Non-Amine Engine Coolant to the middle between FULL and LOW. 22. Stop the engine. 23. Approximately 3 minutes later, add the Non-Amine Engine Coolant up to the mouth of the coolant filler port.
Page 335 MAINTENANCE MAINTENANCE PROCEDURE While running the engine at low idle, remove the cap of oil filler port (F). Pull out the dipstick (G) and wipe the oil off with a cloth. Fully insert the dipstick (G) into the dipstick pipe, then re- move it.
Page 336: Method For Cleaning Engine Damper Breather
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING ENGINE DAMPER BREATHER WARNING Immediately after the engine is stopped, parts and oil are still very hot. Wait for the temperature to go down, and then start the work. Remove the bolts (1) (3 pieces) and remove the cover (2). Remove the bolts (3) (4 pieces) and remove the cover (4).
Page 337: Method For Cleaning Axle Breather
MAINTENANCE MAINTENANCE PROCEDURE Stop the engine and remove plug (1). Wipe off oil of dipstick (G) installed to plug (1) by using a piece of cloth. Set dipstick (G) as shown in the figure. (2): Axle (3): Spot facing surface The level is appropriate if it is between 2 grooves (H) and (L) of the dipstick.
Page 338: Method For Cleaning Air Conditioner Condenser
MAINTENANCE PROCEDURE MAINTENANCE Remove mud and dust around the breather by using a brush, etc. Remove the breather, immerse it in detergent liquid, and clean it. • Clean the breathers in 2 locations, the front and rear sides. • While the breather is removed, use care to prevent entry of dusts through the mounting location of the breather.
Page 339: Method For Cleaning Radiator Fin And Cooler Fin
MAINTENANCE MAINTENANCE PROCEDURE Remove the mounting bolts (4) of condenser (3) (2 places each on the right and left). Hold the lower part of the condenser (3) and pull it back- ward. A gap is made between the condenser (3) and radiator (5). Clean the condenser with water through this gap.
Page 340: Method For Reversing Automatic Operation Fan
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REVERSING AUTOMATIC OPERATION FAN For the automatic reverse rotation of the fan, see “RADIATOR FAN AUTOMATIC REVERSE MODE (3-61)”. REMARK • When the fan rotation direction is switched, the fan reverse rotation pilot lamp flashes. After a heavy load operation, the fan rotation direction may not change to protect the machine.
Page 341 MAINTENANCE MAINTENANCE PROCEDURE Blow off mud, dirt, leaves, etc. in radiator fins (4) with com- pressed air. NOTICE Steam or water may be used instead of the com- pressed air. However, when using the powerful steam cleaning equipment (high-pressure machine wash) for the heat exchange equipment (radiator and cooler), keep a suf- ficient distance to the target.
Page 342: Method For Inverting And Replacing Bolt On Cutting Edge
MAINTENANCE PROCEDURE MAINTENANCE Hold the lower part of the condenser (3) and pull it back- ward. A gap is made between the condenser (3) and radiator (5). Insert the air nozzle through the gap and perform cleaning. Steam or water may be used instead of the compressed air.
Page 343 MAINTENANCE MAINTENANCE PROCEDURE WARNING • It is dangerous if the work equipment moves by mistake when the tooth is being replaced. Set the work equipment in a stable condition on a ground, stop the engine, then press the work equipment lock switch to lock the work equipment securely (the work equipment lock pilot lamp lights up).
Page 344 Remove the tooth (1). REMARK If it cannot be removed by this method, for safety, ask your Komatsu distributor to have the replacement performed. Clean the bucket adapter (3) thoroughly. Install a new bucket tooth to the bucket adapter (3).
Page 345 MAINTENANCE MAINTENANCE PROCEDURE Fit the socket wrench to the shaft of pin (1), and turn it counterclockwise by 90 ° to unlock the pin. Push out pin (1) to the direction of arrow by hand or ham- mer, and remove tooth (2). Check the torque to unlock the pin by using torque wrench according to the following procedure.
Page 346: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE PROCEDURE MAINTENANCE 10. Check that the shaft of pin (1) is locked securely. Be careful of the direction of brim of the shaft. (A) Free state: The brim of shaft is sideways. (B) Lock state: The brim of shaft is upward. 11.
Page 347 MAINTENANCE MAINTENANCE PROCEDURE Open the engine side cover (4) on the left side of the ma- chine. Check the condition of the refrigerant gas (Hydrofluorocar- bons HFC-134a) that circulates the refrigerant circuit, through the sight glass (6) (inspection window) of the re- ceiver drier piping (5).
Page 348: Method For Replacing Slow-Blow Fuse
MAINTENANCE PROCEDURE MAINTENANCE Maintenance schedule Check point Check items Check before op- 6 months inspec- Replacement in- eration tion terval Belt Looseness, damage Implement 2 years Refrigerant gas Charge amount Implement Looseness, damage, leak- Piping Implement Receiver drier 2 years METHOD FOR REPLACING SLOW-BLOW FUSE NOTICE •...
Page 349: Method For Checking Function Of Ecss Accumulator
Compare the vertical motion of the machine when the ECSS switch is turned to ON position and OFF posi- tion. If there is no change in the vertical motion, the accumulator gas pressure has probably dropped. Ask your Komatsu distributor for inspection. REMARK Perform the inspection while the travel speed is 10 km/h or higher. ECSS (Electronically Controlled Suspen- sion System) does not operate when the travel speed is 5 km/h or lower even if the ECSS switch is turned...
Page 350: Select And Check Tires
• If a tire not specified by Komatsu is used, rim displacement between the tire and rim may occur. Operator comfort, as well, may be degraded. Maximum load (kg)
Page 351: Method For Cleaning And Replacing Fuel Tank Breather Element
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING AND INFLATING TIRE WARNING • When pumping up the tires, check that no other person is standing near the tire, and install an air chuck with a clip that can be secured to the air valve. •...
Page 352 MAINTENANCE PROCEDURE MAINTENANCE Open the engine side cover (1) and rear grille (2) on the left side of the machine. Loosen the nut (4) at the top of the fuel tank breather (3) which is located on the left upper of the fan guard, and re- move it.
Page 353: Checks Before Starting
MAINTENANCE MAINTENANCE PROCEDURE CHECKS BEFORE STARTING For details of the following items, see the pages where they are explained. Checks before starting engine. “METHOD FOR WALK-AROUND CHECK” • Check the work equipment, cylinders, linkage, and hoses for damage, wear, play. •...
Page 354: Every 50 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE “METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE” • Method for checking starting condition and unusual noise of engine. • Method for checking low-speed run and acceleration of engine. • Method for testing parking brake. • Method for checking brake. •...
Page 355: Method For Lubricating Rear Axle Pivot Pin
MAINTENANCE MAINTENANCE PROCEDURE (1) Bucket pin (2 places) (4) Bucket cylinder pin (2 places) (2) Bucket link pin (2 places) (5) Lift cylinder pin (4 places) (3) Bell crank pin (1 place) (6) Boom pivot pin (2 places) Grease bucket pin (1), bell crank pin (3) and boom pivot pin (6) with the work equipment in the posture shown in the figure.
Page 356: Method For Checking Oil Level In Hydraulic Tank, Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE After greasing, wipe off any old grease that is pushed out. METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 357: Method For Cleaning Air Conditioner Fresh Air Filter
MAINTENANCE MAINTENANCE PROCEDURE Check with the sight gauge (G). If it is below the L level, refill the hydraulic oil according to the following procedure. Remove the bolts (1) (2 pieces) and remove the cover (2). Add the hydraulic oil through oil filler port (F). METHOD FOR CLEANING AIR CONDITIONER FRESH AIR FILTER WARNING When using compressed air, there is a danger that dirt may scatter and cause personal injury.
Page 358: Every 250 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE Loosen the knob (4) and take out the filter (5) to clean it. Blow dry compressed air (0.2 MPa {2.1 kg/cm } or less) from the inside of the filter along the pleats. Next, blow along the pleats from the outside, then blow again from the inside.
Page 359: Method For Checking Battery Electrolyte Level
MAINTENANCE MAINTENANCE PROCEDURE (1) Steering cylinder pin (4 places) METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL Perform this procedure before operating the machine. Inspect the battery electrolyte level according to the standard at least once a month. WARNING • Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. If you do so, it will reduce the service life of the battery.
Page 360 LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu dis- tributor or a battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO...
Page 361: Method For Testing Parking Brake
If the purified water is added to above the bottom of the sleeve, use a syringe to remove electrolyte. Neu- tralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 362 MAINTENANCE PROCEDURE MAINTENANCE Check air conditioner compressor belt. Press the middle point between air conditioner compressor pulley (2) and drive pulley (3) with your thumb (approxi- mately 98 N {10 kg}). If deflection (a) is 11 to 15 mm, the belt tension is normal. If the deflection is out of the standard range, adjust it into the standard range.
Page 363: Method For Checking Looseness Of Wheel Hub Bolts, Retightening Bolts
MAINTENANCE MAINTENANCE PROCEDURE Loosen bolts (2) and (3). REMARK When the bolts (2) and (3) are loosened, bracket (5) to which compressor (4) is installed can move, using the mounting position of bolt (3) as a fulcrum. Loosen nut (6) which is installed to the bracket first, and then tighten bolt (7).
Page 364: Every 500 Hours Maintenance
• If the brake oil pressure caution lamp lights up when the brake pedal is depressed 5 times or less, the gas pressure in the accumulator may be low. Ask your Komatsu distributor for inspection. REMARK The inspection must be done within 5 minutes after the engine stops. If the engine is kept stopped, the gas pressure in the accumulator lowers and the inspection cannot be made.
Page 365 Place an oil container right under drain plug (P) to catch the drained oil. Remove drain plug (P) and drain the oil. Check the drained oil. If it contains much metallic powder or foreign material, contact your Komatsu distributor. Tighten drain plug (P). 4-55...
Page 366: Method For Replacing Fuel Prefilter Cartridge
MAINTENANCE PROCEDURE MAINTENANCE Open the engine side cover (2) on the left side of the ma- chine. Turn filter cartridge (3) counterclockwise by using the filter wrench, and remove it. If this operation is performed immediately after stopping the engine, a large amount of oil will come out, so wait for 10 minutes before starting the work.
Page 367 The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 368 MAINTENANCE PROCEDURE MAINTENANCE NOTICE • When filling the filter cartridge with fuel, do not re- move the cap (A) at the center. Always fill with fuel from the small holes (B) (8 places) on the dirty side. • After filling with fuel, remove the cap (A) and in- stall the fuel filter.
Page 369: Every 1000 Hours Maintenance
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 370 MAINTENANCE PROCEDURE MAINTENANCE Turn filter cartridge (2) counterclockwise by using the filter wrench, and remove it. Clean the filter head. Replace inner seal (3) with a new one. Thinly apply oil to the packing surface of the new filter cartridge, then install the filter cartridge to the filter head.
Page 371: Method For Cleaning Transfer Case Breather
MAINTENANCE MAINTENANCE PROCEDURE 10. Check the filter seal surface for fuel leakage. If there is any leakage of fuel, check the tightening condition of the filter cartridge. If there is still leakage of fuel, follow steps 2 and 3 to remove the filter cartridge, then check the packing surface for damage or foreign material.
Page 372 MAINTENANCE PROCEDURE MAINTENANCE Place a container under the drain plug (P) to catch the oil. Remove the drain plug (P) and drain the oil. Loosen the drain plug (P) gradually so that the oil will not spurt out, and then remove it. After draining the oil, install the drain plug (P).
Page 373: Method For Replacing Hst Oil Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE NOTICE • Before starting the engine, check that the oil level is between the marks (C) and (D) on the side of dipstick which has a stamped mark of “COLD STOP”. • When checking the oil level, start the engine first. After finishing the warm-up operation of the transfer, perform the final check by using the side of dipstick which has a stamped mark of “HOT IDLE”.
Page 374: Every 2000 Hours Maintenance
After greasing, wipe off any old grease that is pushed out. METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. METHOD FOR CHECKING AND REPLACING ALTERNATOR BELT •...
Page 375 MAINTENANCE MAINTENANCE PROCEDURE Items to be prepared • Container to catch the drained oil Lower the bucket to the ground with its bottom level, apply the parking brake, then stop the engine. Remove the bolts (1) (2 pieces) and remove the cover (2). Remove the cap of oil filler port (F).
Page 376 MAINTENANCE PROCEDURE MAINTENANCE Remove the bolts (7) (4 pieces) and remove the cover (8). 10. Remove the bolts (9) (4 pieces) and remove the cover (10). 11. Hold the top of rod (11) and pull it up to take out the strain- er (12).
Page 377: Method For Replacing Hydraulic Oil Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE Check that it is at the specified level by referring to “METHOD FOR CHECKING OIL LEVEL IN HYDRAUL- IC TANK, ADDING OIL (4-46)”. 25. Check the cover (10) mount for oil leakage. 26. Install the cover (8) with bolts (7) (4 pieces). 27.
Page 378: Method For Replacing Hydraulic Tank Breather Element
MAINTENANCE PROCEDURE MAINTENANCE Remove the bolts (1) (4 pieces) and remove the cover (2). Place a container to catch the drained oil under the filter cartridge (3). Turn the filter cartridge (3) counterclockwise by using the filter wrench, and remove it. Clean the filter head.
Page 379: Method For Changing Oil In Axle Case
MAINTENANCE MAINTENANCE PROCEDURE Remove the bolts (5) (4 pieces) and remove the cover (6). Before removing the breather, wipe off dirt and dusts around it. Remove the cap of oil filler port (F). Remove the snap ring (8) of breather (7), remove the breather cap (9), and replace filter element (10) with a new one.
Page 380 MAINTENANCE PROCEDURE MAINTENANCE A: Front, B: Rear Place a container under drain plug (P) to catch the drained oil. Remove front and rear plugs (1), then remove drain plug (P) to drain the oil. REMARK Remove the mud and dirt from around plug (1), then remove the plug. After draining the oil, clean and install drain plug (P).
Page 381: Method For Replacing Air Conditioner Fresh/Recirc Air Filters
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC AIR FILTERS Remove both the recirculation air filter and fresh air filter in the same way as in the cleaning procedure, and replace them with new ones. METHOD FOR CLEANING BRAKE CIRCUIT STRAINER WARNING •...
Page 382: Method For Checking Brake Disc Wear Amount
MAINTENANCE PROCEDURE MAINTENANCE Remove the bolts (7) (4 pieces), and remove the washer tank assembly (8). Place a container under the rubber hose (9) and flange (10) to catch the drained oil. Remove the rubber hose (9) and flange (10). Take out the strainer (11) and wash it in the clean diesel fuel.
Page 383: Method For Checking Function Of Ppc Accumulator
(2) to the protrusions of the piston (3) and plate (4). If the inspection gauge (2) can be inserted to the protru- sions, the disc wear has reached to the repair limit. In such case, ask your Komatsu distributor to perform the inspection and replacement of the part. REMARK Perform the operation with 2 workers.
Page 384: Method For Checking Alternator
If the engine is started frequently, have this inspection performed every 1000 hours. METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. METHOD FOR CHECKING VIBRATION DAMPER Check that there are no cracks or peeling in the outside surface of the rubber.
Page 385 MAINTENANCE MAINTENANCE PROCEDURE Items to be prepared • Container to catch the drained oil • Special wrench for KCCV The KCCV ventilator is located in the position shown in the fig- ure. For the use of the special wrench, see the figure. Remove the bolt (1), then remove the fixing clip (2) of the KCCV drain hose.
Page 386 MAINTENANCE PROCEDURE MAINTENANCE There may be oil accumulated or sticking in the case and element. Take care not to spill the oil when replacing the element. REMARK When the ambient temperature is low, water or emulsified matter may stick to the inside of KCCV because of con- densation of water vapor in the blowby gas.
Page 387: Method For Replacing Def Filter
Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without DEF filter attached, or with the filter other than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine.
Page 388 MAINTENANCE PROCEDURE MAINTENANCE After the engine is stopped, DEF system devices automatically purge DEF in DEF injector and DEF pump and return it to DEF tank to prevent malfunction of the devices caused by freezing of DEF or deposition of urea. After the engine is stopped, the devices are operated for a few minutes.
Page 389 MAINTENANCE MAINTENANCE PROCEDURE Insert filter removal tool (5) into the bottom of the DEF pump and thrust in with hand. Check that filter removal tool (5) is fully inserted to the end. Insert the filter to the end where you cannot thrust it in any further.
Page 390: Method For Replacing Def Tank Breather Element
If the machine is operated without DEF tank breather element attached, or with the element other than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine. Never operate the machine without DEF tank breather element at- tached, nor use the element other than Komatsu genuine parts.
Page 391: Every 4000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Remove nut (4) of breather assembly (3) at the top of DEF tank, then remove cover (5). Replace breather (6) with a new one. When installing breather element (6), direct the surface of TOP mark (7) towards up and install. Install cover (5) and nut (4).
Page 392: Method For Lubricating Drive Shaft
Work equipment hydraulic Main pump delivery hose system Main pump delivery hose other than described above Ask your Komatsu distributor for replacement. Main pump LS hose Hydraulic drive fan hose (Exhaust fan) External work equipment hose Lift cylinder hose •...
Page 393: Method For Checking Water Pump
(3) Drive shaft spline (1 places) METHOD FOR CHECKING WATER PUMP Check for leakage of water and oil around the water pump. If any problem is found, ask your Komatsu distributor to perform disassembly, repair, or replacement. METHOD FOR CHECKING STARTING MOTOR Ask your Komatsu distributor to have the starting motor checked.
Page 394: Every 4500 Hours Maintenance
Check fuel spray prevention caps (14 places) visually or with a finger to see if any of them has fell off, or the rubber portion is hardened. If there are any problems, the related parts must be replaced. Ask your Komatsu distributor for replacement. EVERY 4500 HOURS MAINTENANCE Maintenance for every 50, 100, 250 and 500 hours service should be performed at the same time.
Page 395: Method For Replacing Def Hose
MAINTENANCE PROCEDURE METHOD FOR REPLACING DEF HOSE Ask your Komatsu distributor for replacement of the DEF hose. END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. 4-85...
Page 397: Specifications
SPECIFICATIONS...
Page 398: Specifications:wa270-8
12685 (with bolt on cutting edge (BOC)) Normal load kg 3680 Bucket capacity Heaped m Engine model KOMATSU SAA6D107E-3 SAE J1995 115 {153} / 2000 {2000} (gross) kW {HP} / Rated horsepow- ISO 14396 115 {153} / 2000 {2000} {rpm}...
Page 399 SPECIFICATIONS SPECIFICATIONS *1: Value when bucket dump angle is 45 °. 9 J W 0 1 4 5 6...
Page 401: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 402: Bucket And Tire Selection
Hard ground (1.9 m BOC: Abbreviation for Bolt On Cutting edge You need to change the travel speed display on the machine monitor according to the tire size. If you are instal- ling the optional tires, ask your Komatsu distributor for installation.
Page 403: Handle Hydraulic Type Quick Coupler
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC TYPE QUICK COUPLER HANDLE HYDRAULIC TYPE QUICK COUPLER WARNING Before operating the machine, check that the attachment is correctly connected. If it is not correctly in- stalled, the attachment may fall off and cause serious injury. •...
Page 404: Method For Removing Attachment
HANDLE HYDRAULIC TYPE QUICK COUPLER ATTACHMENTS AND OPTIONS QUICK COUPLER LOCK RELEASE PILOT LAMP Quick coupler lock release pilot lamp lights up when the quick coupler attachment switch is in the position of decoupling. In order to release the quick coupler, operate the multifunction mono-lever to TILT side while the quick coupler attachment switch is in the decoupling position.
Page 405: Method For Installing Attachment
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC TYPE QUICK COUPLER Check that the lock pins have been removed. The lock pin indicators (3) may not be visible. g0038103 Lower the attachment completely to the ground and set it in a stable position. g0038104 Tilt the coupler forward slowly and lower it slowly so that it separates from the attachment hook.
Page 406 HANDLE HYDRAULIC TYPE QUICK COUPLER ATTACHMENTS AND OPTIONS Pull lock (A) of the quick coupler switch in the direction of the arrow (b), and push in to RELEASE position (a). • Keep the quick coupler attachment switch pressed un- til the work of the step 8 is completed. •...
Page 407 ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC TYPE QUICK COUPLER Raise the coupler slowly as the machine travels forward, keep raising it until coupler tube comes to be connected with the attachment hook and the attachment is a little lift- ed off from the ground. Check that the attachment is horizontal to the left and right and that each hook is correctly inserted.
Page 408: Handle Fork
HANDLE FORK ATTACHMENTS AND OPTIONS HANDLE FORK EXPLANATION OF COMPONENTS ON MACHINES WITH FORK (1) Multifunction mono-lever (2) Attachment selector switch MULTIFUNCTION MONO-LEVER The multifunction mono-lever is used to operate the boom and fork. NOTICE Do not use “FLOAT” position when lowering the fork.
Page 409: Machine Operations And Controls
ATTACHMENTS AND OPTIONS HANDLE FORK Position (a): RAISE When the multifunction mono-lever is pulled further from the “RAISE” position, the lever stops in that position. The boom stops at the preset position and the lever returns to “HOLD” position at the same time when the remote boom posi- tioner is enabled.
Page 410 HANDLE FORK ATTACHMENTS AND OPTIONS METHOD FOR ADJUSTING FORK POSITIONER Lower the fork to the ground, and make it horizontal. Return the multifunction mono-lever to “HOLD” position. Press the work equipment lock switch and lock the work equipment (the pilot lamp lights up). Stop the engine.
Page 411 ATTACHMENTS AND OPTIONS HANDLE FORK Loosen the nut (1), and adjust the position of proximity switch (3) so that the rear end (A) of the bar (2) is matched to the center of sensory surface (B) of the proximity switch (3).
Page 412 HANDLE FORK ATTACHMENTS AND OPTIONS PICK UP LOAD WARNING • Do not perform rapid turning, rapid acceleration, nor rapid deceleration when carrying the load. Oth- erwise, the load may fall or the machine may become inclined. • Tilting angle of the fork varies depending on the load. If the load is stacked higher than the height of the carriage back, it may slip and fall backward.
Page 413 ATTACHMENTS AND OPTIONS HANDLE FORK CARRY WARNING • Do not perform rapid turning, rapid acceleration, nor rapid deceleration when carrying the load. Oth- erwise, the load may fall or the machine may become inclined. • Tilting angle of the fork varies depending on the load. If the load is stacked higher than the height of the carriage back, it may slip and fall backward.
Page 414 HANDLE FORK ATTACHMENTS AND OPTIONS Drive the machine in reverse slowly, and pull the fork off from the load. Lower the fork. 6-14...
Page 415: Pcs (Proportional Control Switch)
ATTACHMENTS AND OPTIONS PCS (PROPORTIONAL CONTROL SWITCH) PCS (PROPORTIONAL CONTROL SWITCH) PCS (Proportional Control Switch) is used to operate the third attachment. The amount of the hydraulic oil discharged by the switch opera- tion is in proportion to the stroke of the switch. The switch has 2 control modes;...
Page 416 PCS (PROPORTIONAL CONTROL SWITCH) ATTACHMENTS AND OPTIONS OIL FLOW CONTROL MODE PILOT LAMP (FIXED OIL FLOW MODE) Oil flow control mode pilot lamp (fixed oil flow mode) lights up when the flow control mode of PCS is in the fixed oil flow mode.
Page 417: Method For Setting Pcs
ATTACHMENTS AND OPTIONS PCS (PROPORTIONAL CONTROL SWITCH) ATTACHMENT OIL FLOW LEVEL The attachment oil flow level indicates the maximum flow level which has been set. It indicates the level 0 to 8 according to the attachment flow rate level which has been set. It is displayed in green (A) in the normal state, and in orange (B) under the detent control.
Page 418 PCS (PROPORTIONAL CONTROL SWITCH) ATTACHMENTS AND OPTIONS To change the setting name, select “Attachment Name Setting” and press ENTER switch (2). Change the alphabet at the cursor with UP or DOWN switches and move the cursor with menu switch (1). After completing the change, validate it with ENTER switch (2).
Page 419: Auto-Greasing
The settings when shipping from the factory are as follows. Lubrication interval: Every 1 hour Lubrication time: 9 minutes When changing the settings of the lubrication cycle for the heavy-duty operations, consult your Komatsu distrib- utor. Method for operating the auto-greasing system The pump with grease tank is located at the position as shown in the figure.
Page 420 AUTO-GREASING ATTACHMENTS AND OPTIONS LED display (1) Three-digit LED display: Values and operating state (2) Pause time (3) Pump operation (4) Monitoring of system function by means of an external cycle switch (5) Without function (6) Fault message Push button switch (1) Turn on display Display values and parameters Set values and parameters...
Page 421 ATTACHMENTS AND OPTIONS AUTO-GREASING Display Denotation Explanation Control function c = COUNTER Attention! Not used CO = CONTACT This mode causes a malfunction. C = Cycle Display of beginning of menu O = OFF “Monitoring settings” P = Pressure Monitoring The monitoring functions PS and No system monitoring CS are deactivated.
Page 422: Initial 10 Hours Maintenance (Only For The First 100 Hours)
The sequence of opera- tions is stopped. If the fault message will appear again after the reset, consult your Komatsu distributor. INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) For the first 100 hours of operation on a new machine, press the switch shown in the figure every 10 hours to actuate the manual greasing.
Page 423 Komatsu distributor. Maintenance work should be performed if needed or every 50 hours. If any problem occurs, consult your Komatsu distributor. Prepare the grease. For the types of grease, see “METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
Page 425: Replacement Parts
REPLACEMENT PARTS...
Page 426: Periodic Replacement Of Defined Life Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. DEFINED LIFE PARTS LIST Periodical replacement parts...
Page 427: Consumable Parts
The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
Page 428: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 429 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT The symbols used in the lubrication chart are explained as follows. Symbol Meaning of the symbol Symbol Meaning of the symbol Read the Operation and Maintenance Lubricating with grease Manual. Change the engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level...
Page 430 RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS Symbol Meaning of the symbol Symbol Meaning of the symbol Change engine oil filter Change hydraulic oil filter Change breather element in hydraulic tank Change fuel filter Change KCCV filter breather element Change axle oil Change DEF tank breather element Change DEF filter...
Page 431 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Ambient Temperature, de- Recommended Komatsu Flu- grees Celsius Reservoir Fluid Type EOS5W30-LA -25 °C 35 °C (KES Diesel Engine Oil) Engine oil for KDPF used in...
Page 432 Note 8: DEF freezes at -11 °C. If thawing is necessary, DEF system is automatically heated and thawed after the engine is started. RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
Page 433 INDEX INDEX Symbols Alternator belt - Check / Replace......4-64 Always use clean washer fluid........ 4-2 12/24 display mode..........3-84 Appoint leader when working with others..... 2-33 2-stage low idle switch........3-100 Armrest angle - Adjust........3-164 2-stage low idling pilot lamp........3-32 Armrest height and angle - Adjust.......3-171 Ashtray..............
Page 434 INDEX DEF level - Check..........3-194 DEF level caution lamp......... 3-22 Cab door - Open / Close........3-110 DEF level gauge........... 3-43 Cab door handle..........3-111 DEF low level guidance........3-37 Calendar setting............3-81 DEF system caution lamp........3-25 Cap and cover with lock........3-114 DEF system high-temperature stop caution lamp.3-25 Carry..............
Page 435 INDEX Engine - Check starting condition and unusual noise.. Fan control system caution lamp......3-27 ..............3-178 Fan reverse rotation display........3-33 Engine - Operate / Check after starting....3-178 Fan switch............3-212 Engine - Operate / Check before starting... 3-172 Filter................ 4-8 Engine - Start..........3-174,3-238 Fin - Clean by rotating cooling fan in reverse..
Page 436 Komatsu Closed Crankcase Ventilation (KCCV) 3-132 Machine monitor - Operate when operator identifica- Komatsu Diesel Particulate Filter (KDPF) - Handle..tion function is available without skip.....3-88 ..............3-124 Machine monitor - Operate when starting engine in Komatsu genuine lubricants........4-2...
Page 437 PCS - Set.............. 6-17 Maintenance of air conditioner......2-40 PCS (Proportional Control Switch)..... 3-102,6-15 Maintenance procedure........4-15 Perform KOWA (Komatsu Oil Wear Analysis)..4-7 Maintenance schedule.......... 4-12 Periodic replacement of defined life parts.....2-41 Maintenance schedule table......... 4-12 Permissible water depth........3-193 Maintenance screen - Set........
Page 438 INDEX Precautions for storing.......... 2-43 Rear view monitor brightness adjustment switch..3-95 Precautions for storing tires........2-42 Rear wiper switch..........3-97 Precautions for towing and being towed....2-32 Rear working lamp switch........3-97 Precautions for towing machine......3-231 Rearview camera - Adjust........3-167 Precautions for transportation.......2-31 Rearview camera angle - Adjust......
Page 439 INDEX Start engine with jumper cables......2-25 Two workers for maintenance when engine is running Starting motor - Check.......... 4-83 ...............2-35 Starting motor - Replace........4-84 Starting switch............3-93 Steering cylinder pin - Lubricate......4-48 Unauthorized modification........2-21 Steering low oil pressure caution lamp....3-35 Understanding the machine........

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Wa270-8 H83001

Komatsu H75051 Operation & Maintenance Manual

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