Page 1 NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.
Page 2 This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
Page 3 Safety precautions are described in SAFETY from page 1-1. Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions.
Page 4 If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user.
Page 5 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 4.1 MACHINE SERIAL NO. PLATE POSITION Position of plate On the center right of the front frame. Position of stamp This is stamped on the center of the front frame on the right side of the machine.
Page 6 5. CONTENTS 1. Foreword ............................0- 1 2. Safety information ..........................0- 2 3. Introduction ............................0- 3 4. Location of plates, table to enter serial No. and distributor ............0- 4 SAFETY 6. General precautions .......................... 1- 2 7. Precautions during operation ......................1- 7 Before starting engine ......................
Page 7: Table Of Contents
5. CONTENTS 12. Operation ............................2-54 12.1 Check before starting engine ....................2-54 12.2 Starting engine ........................2-68 12.3 Operations and checks after starting engine ............... 2-74 12.4 Moving machine off ........................ 2-75 12.5 Changing gear speed ......................2-77 12.6 Changing direction ........................
Page 8 5. CONTENTS MAINTENANCE 17. Guides to maintenance ........................3- 2 18. Outlines of service ..........................3- 5 18.1 Outline of oil, fuel, coolant ....................3- 5 18.2 Outline of electric system ...................... 3- 8 19. Wear parts list ........................... 3- 9 20.
Page 9 5. CONTENTS 30. Main monitor failure display ......................5-16 30.1 Main monitor failure display ....................5-16 30.2 Error codes list indicated on main monitor ................. 5-17 31. Handling auto-greasing system ....................... 5-19 31.1 Method of operating auto-greasing system................. 5-20 31.2 Precautions when handling auto-greasing system .............
Page 10 SAFETY WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death. This safety section also contains precautions for optional equip- ment and attachments.
Page 11 WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. SAFETY RULES ‡ Only trained and authorized personnel can operate and maintain the machine. ‡ Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
Page 12 UNAUTHORIZED MODIFICATION Any modification made without authorization from Komatsu can create problems with safety. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modification. ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT ‡...
Page 13 WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. FIRE PREVENTION FOR FUEL AND OIL Fuel, oil, antifreeze and wind sprayed can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS. ‡ Keep flame away from flammable fluids. ‡...
Page 14 ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled. Komatsu does not use asbestos in its products, but if you handle materials containing asbestos fibers, follow the guidelines given below: ‡ NEVER use compressed air for cleaning.
Page 15 In such a case, please contact your Komatsu distributor for advice on the method of repair. Even if ROPS is installed, it can only provide proper protection if the operator wears the seat belt.
Page 16 7. PRECAUTIONS DURING WARNING: Failure to follow these safety OPERATION precautions may lead to a serious accident. 7.1 BEFORE STARTING ENGINE SAFETY AT WORKSITE ‡ Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. ‡...
Page 17 WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day’s work. Failure to carry out these checks may lead to serious injury or damage. ‡...
Page 18 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION WHEN STARTING ENGINE ‡ Walk around your machine again just before mounting it, and check for people and objects that might be in the way. ‡...
Page 19 WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. 7.2 AFTER STARTING ENGINE CHECKS AFTER STARTING ENGINE Failure to carry out the checks properly after starting the engine will lead to delays in discovery of abnormalities, and this may lead to serious injury or damage to the machine.
Page 20 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION CHECK WHEN CHANGING DIRECTION To prevent serious injury or death, always do the following before moving the machine or the work equipment. ‡ Sound the horn to warn people in the area. ‡...
Page 21 This may cause the tires to burst. If a tire bursts, it produces an extremely large destructive force, and this may cause serious injury or accident. ‡ If you are going to travel continuously, please consult your Komatsu distributor. 1-12...
Page 22 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION TRAVELING ON SLOPES ‡ Traveling on slopes could result in the machine tipping over or slipping to the side. ‡ When traveling on slopes, keep the bucket approximately 72 – 85 cm (28.3 – 33.5 in) above the ground.
Page 23 WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. PRECAUTIONS WHEN OPERATING ‡ Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or when dropping soil over a cliff, dump one pile, then use the next pile of soil to push the first pile.
Page 24 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION METHOD OF USING BRAKES ‡ Do not put your foot on the brake pedal unless necessary. ‡ Do not depress the brake pedal repeatedly unless necessary. ‡...
Page 25 WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. WORKING ON LOOSE GROUND ‡ Do not operate the machine on soft ground. It is difficult to get the machine out again. ‡ Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse under the mass or vibration of your machine, the machine could fall or tip over and this could result in serious injury or death.
Page 26 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION PRECAUTIONS IN COLD AREAS ‡ After completing operations, remove all water, snow, or mud stuck to the wiring harness, connector 1, switches, or sensors, and cover these parts. If the water freezes, it will cause malfunctions of the machine when it is next used, and this may lead to unexpected accidents.
Page 27 When traveling on public roads, check first with the relevant authorities and follow their instructions. ‡ The machine can be divided into parts for transportation, so when transporting the machine, please contact your Komatsu distributor to have the work carried out. 1-18...
Page 28 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.4 BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate hydrogen gas, so mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. ‡...
Page 29 WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause a fire, so always do as follows. ‡...
Page 30 ‡ If the engine on the problem machine will not start or there is a failure in the brake system, please contact your Komatsu distributor for repairs. ‡ It is dangerous to tow a machine on a slope, so choose a place where there is a gradual slope.
Page 31 MAINTENANCE follow these safety precautions. 8.1 BEFORE CARRYING OUT MAINTENANCE NOTIFICATION OF FAILURE Carrying out maintenance not described in the Komatsu operation and maintenance manual may lead to unexpected failures. Please contact your Komatsu distributor for repairs. WARNING TAG ‡ If others start the engine or operate the controls while you are performing service or lubrication, you could suffer serious injury or death.
Page 32 WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE KEEP WORK PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip.
Page 33 WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ‡ When carrying out inspection and maintenance, park the machine on level ground where there is no danger of falling rocks or landslides, or of flooding if the land is low, then lower the work equipment to the ground and stop the engine.
Page 34 Hoses and other parts of the fuel, engine, hydraulic, and brake system are critical parts for ensuring safety, so they must be replaced periodically. Replacement of safety critical parts requires skill, so please ask your Komatsu distributor to carry out replacement.
Page 35 WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. USE OF LIGHTING ‡ When checking fuel, oil, battery electrolyte, or window washer fluid, always use lighting with anti- explosion specifications. If such lighting equipment is not used, there is danger of explosion. ‡...
Page 36 WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE 8.2 DURING MAINTENANCE PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer. Extra precaution should be used when grinding, welding, and using a sledge-hammer.
Page 37 WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. MAINTENANCE WITH CHASSIS RAISED ‡ When carrying out operations with the work equipment or chassis raised, lock the front and rear frames with the safety bar, return the control levers to HOLD, set the control lever safety lock to the LOCK position, and block the work equipment and chassis.
Page 38 WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE DO NOT DROP TOOLS OR PARTS INSIDE MACHINE ‡ When opening the inspection window or tank oil filler to carry out inspection, be careful not to drop any nuts, bolts, or tools inside the machine.
Page 39 ‡ Depending on the type of failure, please contact your Komatsu distributor for repairs. RULES TO FOLLOW WHEN ADDING FUEL OR OIL Fuel, oil, antifreeze, and window washer fluid can be ignited by a flame.
Page 40 If it is difficult to locate the leakage, always please contact your Komatsu distributor for repairs. ‡ If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
Page 41 WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. TIRE MAINTENANCE Disassembly, repair, and assembly of tires requires specialist equipment and skill, so please ask your specialist tire repair shop to carry out repairs. CHECKS AFTER INSPECTION AND MAINTENANCE Failure to carry out inspection and maintenance fully, or failure to check the function of various maintenance locations may cause unexpected problems and may even lead to personal injury or damage, so always do as follows.
Page 42 WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE 8.3 TIRES HANDLING TIRES If a tire or a rim is handled wrongly, the tire may burst or may be damaged and the rim may be broken and scattered, and that can cause serious injury and death.
Page 43 WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. PRECAUTIONS FOR STORAGE OF TIRES ‡ As a basic rule, store the tires in a warehouse which unauthor- ized persons cannot enter. If you must store the tires outside, always erect a fence around the tires and put up a “No Entry”...
Page 44 There are other labels in addition to the safety labels listed as follows, so handle them in the same way. Safety labels may be available in languages other than English. To find out what labels are available, contact your Komatsu distributor. 9.1 POSITION FOR ATTACHING SAFETY LABELS 1-35...
Page 45 Read manual and labels before operation and maintenance. Follow instructions and warnings in manual and in labels on machine. Keep manual in machine cab near operator. Contact Komatsu distributor for a replacement manual. • • • 2. Precautions for safety lock lever...
Page 46 9. POSITION FOR ATTACHING SAFETY LABELS 4. Do not enter 6. Precautions when coolant is at high tem- perature Hot water hazard. To prevent hot water from spurting out: Turn engine off. • Allow water to cool. • Slowly loosen cap to relieve •...
Page 47 9. POSITION FOR ATTACHING SAFETY LABELS 9. Precautions when handling battery 12. “Do not open when engine is running” sign (09667-03001) CAUTION While engine is running: 1. Do not open cover. 2. Keep away from fan and fan-belt. 09667-03001 (This plate is stick on the machine by the battery maker.) 10.
Page 48 SERIAL MAX. MODEL MODEL WASS ‡ Altering ROPS may weaken it. Consult Komatsu Distributor before altering. WARNING ‡ ROPS may provide less protection if it has been structurally damaged or involved in roll-over. ‡ Always wear seat belt when moving.
Page 49 MEMO 1-40...
Page 50: Operation
OPERATION...
Page 51 10. GENERAL VIEW 10.1 GENERAL VIEW OF MACHINE If directions are indicated in this section, they refer to the directions shown by the arrows in the diagram below.
Page 52 10. GENERAL VIEW 10.2 GENERAL VIEW OF CONTROLS AND GAUGES...
Page 53 11. EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is impor- tant to understand fully the methods of operating the equipment and the meanings of the displays. 11.1 MACHINE MONITOR The machine monitor system consists of the main monitor (in front of the operator’...
Page 54 Finally, there will be two beeps to indicate that the monitor check has been completed. If the monitor lamps do not light up, there is probably a failure or disconnection, so please contact your Komatsu distributor for inspection. When the starting switch is turned to the ON position, if the...
Page 55 11. EXPLANATION OF COMPONENTS 11.1.1 WARNING DISPLAYS 1. CENTRAL CHECK LAMP (CHECK) WARNING If this monitor flashes, carry out inspection and maintenance of the appropriate location as soon as possible. ‡ If any abnormality is found in the CHECK items before starting the engine (engine oil level, engine water level), the monitor lamp for the abnormal location will flash and the central CHECK lamp will also flash.
Page 57 11. EXPLANATION OF COMPONENTS 4. ENGINE OIL LEVEL CAUTION PILOT LAMP This warns the operator that the level of the oil in the engine oil pan has dropped. When carrying out checks before starting: If the oil level in the engine oil pan is low, the caution pilot lamp and central CHECK lamp will flash.
Page 58 11. EXPLANATION OF COMPONENTS 7. BATTERY CHARGE CAUTION PILOT LAMP This warns the operator that there is an abnormality in the charging system when the engine is running. Check before starting: Lights up Engine started or running: When the engine is started, the alterna- tor generates electricity and the lamp goes out.
Page 59 11. EXPLANATION OF COMPONENTS 11.1.2 METER DISPLAY PORTION PILOT DISPLAY When the starting switch is ON, the pilot display lights up when the display items are functioning. 1. PARKING BRAKE PILOT LAMP This lamp lights up when the parking brake is applied. 2.
Page 60 11. EXPLANATION OF COMPONENTS 3. FRONT AND SIDE WORKING LAMP PILOT LAMP This lamp lights up when the front working lamp is switched on. 4. REAR WORKING LAMP PILOT LAMP This lamp lights up when the rear working lamp is switched on. 5.
Page 61 11. EXPLANATION OF COMPONENTS METERS 8. FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank. E: Tank is EMPTY F: Tank is FULL The lamp should light up in the green range during operation. If it enters the red range during operation, the fuel gauge lamp and central CAUTION lamp will flash.
Page 63 11. EXPLANATION OF COMPONENTS 11.2 SWITCHES 1. STARTING SWITCH This switch is used to start or stop the engine. OFF position The key can be inserted and removed at this position. When the key is turned to this position, the electric circuit is turned off and the engine stops.
Page 64 11. EXPLANATION OF COMPONENTS 2. TRANSMISSION CUT-OFF SWITCH WARNING If the machine has to be started on a slope, always turn the transmission cut-off switch to OFF and depress the left brake pedal. Then depress the accelerator pedal while releasing the left brake pedal to start the machine off slowly.
Page 65 11. EXPLANATION OF COMPONENTS 5. TRANSMISSION MANUAL SELECTION SWITCH (Machine equipped with auto shift) Press the push button to turn ON or OFF. If the switch is pressed once, the pilot lamp lights up and the system is switched ON. If it is pressed again, the pilot lamp goes out and the system is switched OFF.
Page 66 11. EXPLANATION OF COMPONENTS 7. HORN SWITCH When the button in the center of the steering wheel is pressed, the horn will sound. AE061220 8. HAZARD LAMP SWITCH WARNING Use the hazard lamps only in emergencies. Using the hazard lamps when traveling will cause problems for other machines. This switch is used in emergencies, such as when the machine breaks down.
Page 67 11. EXPLANATION OF COMPONENTS 10. FRONT WIPER SWITCH Turn switch A to operate the front wiper. ‡ Switch position Display window Operation Intermittent wiper Low-speed wiper High-speed wiper ‡ If button B is kept pressed, washer fluid will be sprayed out on to the front glass.
Page 68 ‡ If the parking brake has been used as an emergency brake when traveling at high speed (near the maximum speed), contact your Komatsu distributor to have the parking brake checked for any abnormality. 2-19...
Page 69 11. EXPLANATION OF COMPONENTS 15. PREHEATER SWITCH (APS (automatic priming system) switch) When using APS, engine intake air is heated. Usually, the switch should be in the OFF position. a OFF position: The pre-heat function is not working. b AUTO position: When engine water temperature is below 13˚C, APS starts.
Page 70 11. EXPLANATION OF COMPONENTS 17. RIGHT SIDE POWER WINDOW SWITCH 18. LEFT SIDE POWER WINDOW SWITCH These switches can be used while the engine switch is at the ON position. WARNING When closing the window glass, take care not to catch anyone’s hand or face in it.
Page 71 11. EXPLANATION OF COMPONENTS 20. ENGINE EMERGENCY STOP SWITCH WARNING Never use this switch when stopping the engine normally. After using it, return it to the normal position when the engine has stopped completely. Use this switch when it is impossible to stop the engine by turning the starting switch OFF.
Page 72 11. EXPLANATION OF COMPONENTS 11.3 CONTROL LEVERS, PEDALS 1. SPEED CONTROL LEVER This lever controls the travel speed of machine. MANUAL SHIFT SYSTEM This machine has a 4-FORWARD, 4-REVERSE speed transmis- sion. Place the speed control lever in a suitable position to obtain the desired speed range.
Page 73 11. EXPLANATION OF COMPONENTS AUTOMATIC SHIFT SYSTEM (IF EQUIPPED) Automatic gear shifting can be carried out in the 2nd to 4th speed range of the four forward and reverse speeds depending on the travel conditions. Position 1: 1st speed Position 2: 2nd speed Position 3: 3rd speed Position 4: 4th speed The range of speeds during automatic gear shifting is deter-...
Page 74 11. EXPLANATION OF COMPONENTS 2. DIRECTIONAL LEVER This lever is used to change the direction of travel of the machine. The engine cannot be started if the directional lever is not at N (neutral). Position 1 : Forward Position N : Neutral Position 2 : Reverse REMARK The length of the lever can be adjusted to 3 stages (positions A,...
Page 75 11. EXPLANATION OF COMPONENTS 5. BUCKET CONTROL LEVER This lever operates the bucket. 1 TILT ( U ): When the bucket control lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset posi- tion of the positioner, and the lever is returned to the HOLD position.
Page 76 11. EXPLANATION OF COMPONENTS 7. BRAKE PEDALS WARNING ‡ When traveling downhill, use the engine as a brake, and always use the right brake pedal. ‡ Do not use the brake pedals repeatedly unless necessary. ‡ Do not put your foot on this pedal unless necessary. Right brake pedal The right brake pedal operates the wheel brakes, and is used for normal braking.
Page 77 11. EXPLANATION OF COMPONENTS 11.4 STEERING COLUMN TILT LEVER WARNING Stop the machine before adjusting the angle of the steering wheel. This lever allows the steering column to be tilted forward or backward. Pull the lever up and move the steering wheel to the desired position.
Page 78 If any abnormality occurs which needs the fuel stop lever to be used, please contact your Komatsu distributor. If the engine is stopped using the fuel stop lever, bleed the air from the circuit before starting the engine again.
Page 79 11. EXPLANATION OF COMPONENTS 11.8 TOWING PIN 1. Insert towing pin 1 into hole 2 in the counterweight. 2. Use linch pin 3 to set so that the towing pin does not come out. Carry out this operation in reverse to remove the pin. 2-30...
Page 80 11. EXPLANATION OF COMPONENTS 11.9 GREASE PUMP The grease pump is stored in the engine hood on the left side of the machine. After using it, wipe off all grease stuck to its outside of the pump, then store it. 11.10 BACKUP ALARM This sounds an alarm when the directional lever is set to the R position.
Page 81 11. EXPLANATION OF COMPONENTS 11.13 FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 82 11. EXPLANATION OF COMPONENTS Fuse box II Fuse Name of circuit capacity Front working lamp Rear working lamp Air conditioner 1 (if equipped) Air conditioner 2 (if equipped) Wiper, washer Side working lamp Cigarette lighter, radio (if equipped) Rotating lamp (if equipped) Auto-greasing (if equipped) L.H.
Page 83 11. EXPLANATION OF COMPONENTS Fuse box II Fuse Name of circuit capacity Front working lamp Rear working lamp Air conditioner 1 (if equipped) Air conditioner 2 (if equipped) Wiper, washer Side working lamp Cigarette lighter, radio (if equipped) Rotating lamp (if equipped) Auto-greasing (if equipped) L.H.
Page 84 11. EXPLANATION OF COMPONENTS 11.15 LUNCH BOX TRAY There is a space for a lunch box at the right rear of the cab. Even a large lunch box 35 cm (13.8 in) long, 22 cm (8.7 in) wide and 18 cm (7.1 in) high can be placed easily and fixed with a band.
Page 85 11. EXPLANATION OF COMPONENTS 11.18 AM/FM CAR RADIO (IF EQUIPPED) 11.18.1 EXPLANATION OF COMPONENTS 1. POWER SWITCH/VOLUME CONTROL KNOB Push this knob to switch the radio on. Turn the knob clockwise to increase the sound, and counterclockwise to reduce it. 2.
Page 86 11. EXPLANATION OF COMPONENTS 4. CLK(clock button)/(displaying frequency) When this button is pressed, the display changes to clock. When pressed again, frequency is displayed. 5. ME The preset stations are called in turn by pressing this button. When the desired broadcasting station is reached, press this button again, and it stops at that station.
Page 87 11. EXPLANATION OF COMPONENTS 11.18.2 METHOD OF USE 1. Turn the ignition key to ACC or ON, and then turn the power 1 of the radio to ON. 2. Set the “BAND” switch 2 to MW(AM) or FM. 3. Select the broadcasting station using the preset switch or the tuning switch 3.
Page 88 11. EXPLANATION OF COMPONENTS METHOD OF AUTOMATIC MEMORY The receiptable broadcasting station at your site are called in turn by pressing “ME” button for 2 seconds and they are automati- cally memorized in the preset memory. AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO When the radio wave of receiving FM stereo signal is weak (such as when receiving at the area or the mountainous region that are far from the broadcasting stations), stereo is switched to monaural...
Page 89 11. EXPLANATION OF COMPONENTS 11.19 AM/FM RADIO-CASSETTE STEREO (IF EQUIPPED) 11.19.1 EXPLANATION OF COMPONENTS 1. POWER SWITCH/VOLUME CONTROL KNOB Turn this knob clockwise until it clicks, and the power is turned on. Turn it further to increase the sound. 2. TONE CONTROL KNOB Adjust the tone of the sound by turning this knob.
Page 90 11. EXPLANATION OF COMPONENTS 4. TREBLE CONTROL KNOB Slide this knob to the right to enhance high frequency sound and to the left to suppress high frequency sound. 5. EJECT BUTTON Press this button to eject the cassette tape. 6. CASSETTE DOOR Insert a cassette tape with the exposed magnetic tape side facing to the right.
Page 91 11. EXPLANATION OF COMPONENTS 10. SEEK SWITCH When this SEEK button is pressed, the system automatically searches for a receivable station, and automatically stops search- ing once a station is picked up. 11. LOUD BUTTON This button is used to operate the system at a lower sound volume but with enhanced bass and treble sound.
Page 92 11. EXPLANATION OF COMPONENTS 16. PRESET SWITCH (IN RADIO MODE) One station each in the FM1, FM2, FM3 and MW (AM) bands, respectively, can be preset for buttons 1 to 6 shown at right. (Refer to the section “Presetting to selected stations”.) 17.
Page 93 11. EXPLANATION OF COMPONENTS 11.19.2 OPERATION METHOD PRESETTING TO SELECTED STATIONS When listening to a preset station, select one of the AM, FM1, FM2 and FM3 bands using band select switch 1, then simply press the number key corresponding to the preset selected station. The system can memorize 6 stations in AM band and 18 stations in FM bands (FM1: 6 stations, FM2: 6 stations and FM3: 6 stations).
Page 94 11. EXPLANATION OF COMPONENTS RECEIVING RADIO BROADCASTS 1. Turn ON the ignition key, then turn on power switch 1 of the car stereo. 2. Select either AM or FM band with the band select switch 2. 3. Tune to the desired station using the preset switch or tuner switch 3.
Page 95 11. EXPLANATION OF COMPONENTS ADJUSTING TIME 1. Turn on the ignition key, then turn on the power switch of the car stereo. If the frequency is displayed on the display, change the display to the clock using the display changeover switch. 2.
Page 96 11. EXPLANATION OF COMPONENTS WHEN PLAYING A CASSETTE TAPE 1. Turn on the ignition key, then turn on the power switch of the car stereo. 2. Insert your cassette tape in the cassette door with the exposed tape on the right side. The tape will start playing automatically. If the tape running direction indication is >, the upper channel of the tape is being played and if <...
Page 97 11. EXPLANATION OF COMPONENTS 11.19.3 PRECAUTIONS WHEN USING ‡ Retract the antenna when traveling in places with low overhead height. ‡ For safety reasons, when operating, keep the sound to a level where you can enjoy the sound but still hear the sound from outside the vehicle.
Page 98 11. EXPLANATION OF COMPONENTS 11.20 CAR HEATER 11.20.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL 1. FAN SWITCH This can be used to adjust the air flow to four stages. This switch also acts as the main switch for the car heater. When the switch is pressed, the indicator lamp above the switch lights up to indicate the air flow.
Page 99 11. EXPLANATION OF COMPONENTS 4. TEMPERATURE CONTROL SWITCH The temperature can be adjusted steplessly from low tempera- ture to high temperature. The temperature level indicator lamps light up to display the temperature of the air coming from the vents. The more the blue lamps light up, the lower the temperature is. The color of the indicator lamp changes while the switch is being pressed.
Page 100 11. EXPLANATION OF COMPONENTS 11.21 AIR CONDITIONER (IF EQUIPPED) 11.21.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL 1. FAN SWITCH This can be used to adjust the air flow to four stages. This switch also acts as the main switch for the air conditioner. When the switch is pressed, the indicator lamp above the switch lights up to indicate the air flow.
Page 101 11. EXPLANATION OF COMPONENTS 4. FRESH/RECIRC SELECTOR SWITCH This switch is used to select between recirculating the air inside the cab or taking in fresh air from outside. When the RECIRC position is selected, the indicator lamp above the switch lights up. When the switch is pressed again, the indicator lamp goes out, and fresh air is taken in.
Page 102 11. EXPLANATION OF COMPONENTS 11.21.2 METHOD OF OPERATION Switch Air conditioner Temperature FRESH/RECIRC Vent mode Condition switch switch control switch switch selector switch of use Rapid All blue RECIRC FACE Cooling More than Normal HI-LO FRESH FACE half are blue More than Dehumidifying, heating HI-LO...
Page 103 Use the air bleed valve to release the gas. ‡ Every 2000 hours or once a year, please contact your Komatsu distributor to have the gas pressure checked. The accumulator for the brake is installed on the side of the brake component box on the left side of the rear frame.
Page 104: Check Before Starting Engine
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Page 105 12. OPERATION 1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses. If any abnormality is found, repair it. 2. Remove dirt and dust from around engine, battery, radiator Check if there is any dirt or dust accumulated around the engine or radiator.
Page 106 Check for any loose or damaged bolts. If any loose bolts are found tighten them to 1715 ± 195 N·m (175 ± 20 kgf·m, 1266 ± 145 lbft). If any bolts are damaged, replace them with genuine Komatsu bolts. 13. Clean cab window Clean the cab window to ensure good visibility when operating the machine.
Page 107 12. OPERATION 14. Inspection of tires WARNING If worn or damaged tires are used, they may burst and cause serious injury or death. To ensure safety, do not use the following tires. Wear: ‡ Tires with a tread groove of less than 15% of that of a new tire ‡...
Page 108 3 seconds and the alarm buzzer sounds for about 1 second. If any monitor lamp does not light up, ask your Komatsu distribu- tor to inspect that monitor lamp. Do not carry out the checks before starting using only the monitor;...
Page 109 12. OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the inspection window at the rear right side of the ma- chine. 2. Remove dipstick G and wipe the oil off with a cloth. 3. Insert dipstick G fully in the oil filler pipe, then take it out again. 4.
Page 110 12. OPERATION CHECK BRAKE OIL TANK LEVEL, ADD OIL WARNING Always use engine oil to refill the brake oil tank. 1. Check from the ground that the brake oil level in the brake oil tank on the left side of the machine is within sight gauge 1 installed to the side of the brake tank.
Page 111 12. OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If you spill fuel, thoroughly clean up any spillage. 1. Turn the engine starting switch to the ON position, then check the fuel level with fuel gauge G.
Page 112 When carrying out walk-around checks or checks before starting, always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of the cause. CHECK INFLATION PRESSURE OF TIRES Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.
Page 113 12. OPERATION CHECK EFFECT OF PARKING BRAKE WARNING Even if the parking brake switch is turned ON, there is danger until the parking brake pilot lamp lights up, so keep the brake pedal depressed. Measurement conditions ‡ Tire inflation pressure: Specified pressure ‡...
Page 114 12. OPERATION 12.1.3 ADJUSTMENT BEFORE OPERATION AIR SUSPENSION SEAT WARNING ‡ Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. ‡ Adjust the seat before starting operations or when changing operators.
Page 115 12. OPERATION F: Adjusting height of headrest Move the headrest up and down to the desired height. The adjustment range is 50 mm (2.0 in). G: Adjusting headrest angle Rotate the headrest to the front or rear. H: Adjusting angle of armrest Adjust the angle of the armrest by rotating knob 5.
Page 116 12. OPERATION ADJUST SEAT BELT Always install a seat belt on machines equipped with ROPS. WARNING ‡ Before fitting the seat belt, check that there is no abnormality in the mounting bracket and mounting belt of the belt. If the belt is worn or damaged, replace it.
Page 117 When this happens, 88 is displayed on the speedometer, and 8 is displayed on the transmission shift indicator. If the monitor lamps do not light up, there is probably a failure or disconnection, so please contact your Komatsu distributor for inspection. 2-67...
Page 118: Starting Engine
12. OPERATION 12.2 STARTING ENGINE 12.2.1 NORMAL STARTING WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.
Page 119 12. OPERATION 12.2.2 STARTING IN COLD WEATHER WARNING ‡ Check that there are no persons or obstacles in the surround- ing area, then sound the horn and start the engine. ‡ Never use starting aid fluids as they may cause explosions. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.
Page 120 12. OPERATION 4. Put fuel cut-off switch 3 in ON position. When releasing the switch, it will return to ON position. 5. When preheater switch 4 is put in the ON position, pre-heating monitor 5 will light and automatic pre-heating will start. If pre-heating monitor 5 lights, return preheater switch 4 to AUTO position.
Page 121 12. OPERATION 8. When the engine is started, release the key of starting switch 2 and the key will return automatically to ON. If the engine does not start through the steps specified above, turn key of starting switch 2 to OFF position and repeat Steps 2 to 8 at an interval of approx.
Page 122 12. OPERATION Starting using manual preheating When the engine water temperature is above 13˚C even if the ambient temperature is below 15˚C, automatic preheating cannot be carried out. If it is difficult to start the engine, use the following procedure. 1.
Page 123 The standard specification machine is designed to work in ambient temperature from –20 to 40˚C. When operating the machine at temperatues below –20˚C, spe- cial equipment is needed. Contact your Komatsu distributor for details. For machines where the air dryer is installed as an option, in cold temperatures below –10˚C, when operating the machine after it has...
Page 124: Operations And Checks After Starting Engine
12. OPERATION 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE After starting the engine, do not immediately start operations. First, carry out the following operations and checks. NOTICE Do not suddenly accelerate the engine before the warming-up operation is completed. Do not run the engine at low idling or high idling continuously for more than 20 minutes.
Page 125: Moving Machine Off
12. OPERATION 12.4 MOVING MACHINE OFF WARNING ‡ When moving the machine off, check that the area around the machine is safe, then sound the horn before starting. Do not allow people near the machine. There is a blind spot behind the machine, so be particularly careful when traveling in reverse.
Page 126 12. OPERATION 5. Set speed control lever 0 to the desired position. 6. Set directional lever A to the desired position. 7. Release right brake pedal 8, then depress accelerator pedal 3 to move the machine off. 2-76...
Page 127: Changing Gear Speed
12. OPERATION 12.5 CHANGING GEAR SPEED WARNING When traveling at high speed, do not change the gear speed suddenly. When shifting gear, use the brakes to reduce the travel speed, then shift gear. Shift the gear as follows. Move speed control lever 1 to the desired position. Only 1st or 2nd speeds are used for digging and loading opera- tions, so actuate speed control lever stopper.
Page 128: Changing Direction
12. OPERATION 12.6 CHANGING DIRECTION WARNING ‡ When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so be particularly careful when changing direction to travel in reverse. ‡...
Page 129: Stopping Machine
12. OPERATION 12.8 STOPPING MACHINE WARNING ‡ Avoid stopping suddenly. Give yourself ample room when stopping. ‡ Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.
Page 130: Operation Of Work Equipment
12. OPERATION 12.9 OPERATION OF WORK EQUIPMENT Lift arm control lever 1 and bucket control lever 2 can be used to operate the lift arm and bucket as follows. LIFT ARM OPERATION (LEVER 1) 1 Raise ( J ) 2 Hold ( N ) The lift arm is kept in the same position. 3 Lower ( M ) 4 Float ( * ): The lift arm moves freely under external force.
Page 131: Work Possible Using Wheel Loader
12. OPERATION 12.10 WORK POSSIBLE USING WHEEL LOADER In addition to the following, it is possible to further increase the range of applications by using various attachments. 12.10.1 DIGGING OPERATIONS WARNING Always set the machine facing directly to the front when carrying out digging or scooping operations.
Page 132 12. OPERATION 4. At the same time as thrusting the bucket into the material, raise the lift arm to prevent the bucket from going in too far. By raising the lift arm, ample traction will be produced by the front tires. REMARK If the bucket is thrust too much and the lift arm stops rising or the machine stops moving forward, release the accelerator pedal a...
Page 133 12. OPERATION ‡ When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the machine forward. Always be careful not to load the bucket on one side and cause an unbalanced load. This operation should be carried out in 1st gear.
Page 134 12. OPERATION 12.10.2 LEVELING OPERATIONS NOTICE Always operate the machine in reverse when carrying out leveling operations. If it is necessary to carry out leveling operations when traveling forward, do not set the bucket dumping angle to more than 20°. AE061970 1.
Page 135 12. OPERATION 12.10.5 LOADING OPERATIONS Select the method of operation which will give the minimum amount of turning and travel in order to provide the most efficient method for the jobsite. WARNING ‡ Always keep the working area flat. Do not turn suddenly or apply the brake suddenly when traveling with a raised load.
Page 136: Precautions For Operation
If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine. NOTICE If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the parking brake checked for any abnormality. 12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES LOWER THE CENTER OF GRAVITY WHEN TURNING.
Page 137 The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface. Contact your Komatsu distributor or tire dealer for information. ‡ When traveling with standard tires L-5 on a paved road surface, use the table as a guide.
Page 138: Adjusting Work Equipment Posture
12. OPERATION 12.12 ADJUSTING WORK EQUIPMENT POSTURE WARNING ‡ Stop the machine on flat ground and put blocks in front and behind the wheels. ‡ Apply the parking brake. ‡ Secure the front and rear frames with the safety bar. ‡...
Page 139 12. OPERATION 12.12.2 ADJUSTING BUCKET POSITIONER 1. Lower the bucket to the ground and adjust the bucket to the desired digging angle. Set the bucket control lever at HOLD, stop the engine and adjust as follows. 2. Loosen two bolts 1 and adjust mounting bracket 4 of the proximity switch so that the rear tip of angle 2 is in line with the center of the sensing surface of proximity switch 3.
Page 140: Parking Machine
12. OPERATION 12.13 PARKING MACHINE WARNING ‡ Avoid stopping suddenly. Give yourself ample room when stopping. ‡ Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.
Page 141: Checks After Completion Of Operation
12. OPERATION 4. Operate lift arm control lever 5 to lower the bucket to the ground. 5. Lock lift arm control lever 5 and bucket control lever 6 with safety lock 7. 12.14 CHECKS AFTER COMPLETION OF OPERATION Check the engine water temperature, engine oil pressure, torque converter oil temperature, and fuel level with the meter and lamps.
Page 142: Check After Stopping Engine
12. OPERATION 12.16 CHECK AFTER STOPPING ENGINE 1. Walk around the machine and check the work equipment, body work, and undercarriage, and check also for leakage of oil and water. If any leakage or abnormality is found, carry out repairs. 2.
Page 143: Handling The Tires
ﬁ When the bead is damaged ﬁ For tubeless tires, when there is air leakage or improper repair Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. 12.18.2...
Page 144: Removal And Installation Of The Bucket
12. OPERATION 12.19 REMOVAL AND INSTALLATION OF THE BUCKET WARNING Park the machine on level ground, set the safety bar on the frame, ground the bucket, shut down the engine, apply the parking brake and place blocks under the tires. Remove or install the bucket in the following manner, if so required for the convenience of transportation.
Page 145 12. OPERATION 3. Sling the bucket link, then pull out the bucket link pin. Secure the bucket link to the tilt lever with wires. 4. Pull out and remove bucket hinge pin 5 on both sides of the bucket. 5. Disconnect lift arm and bucket. 2-96...
Page 146 12. OPERATION INSTALLING THE BUCKET 1. Set cord ring 2 on top of lift arm boss 1 as shown in the diagram. After completions of assembly of the bucket and adjustment with shims in step 8, move the cord ring down to the groove. 2.
Page 147 Assemble a pin that has no grease hole at the bucket link. 11. Coat the bucket hinge pin and bucket link pin with grease. For details, see “24.5 EVERY 100 HOURS SERVICE”. For details of removing and installing the bucket, please contact your Komatsu distributor. 2-98...
Page 148 If this is not done, the tires will be damaged, so contact your Komatsu distributor or tire dealer when selecting tires. 2-94...
Page 149: Transportation
13.1 LIFTING MACHINE The machine must be disassembled before the chassis can be lifted, so please contact your Komatsu distributor to have the ma- chine disassembled. 2-99...
Page 150: Cold Weather Operation
14. COLD WEATHER OPERATION 14.1 PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows. 14.1.1 FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see “20.
Page 151 14. COLD WEATHER OPERATION 14.1.3 BATTERY WARNING ‡ To avoid gas explosions, do not bring fire or sparks near the battery. ‡ Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor.
Page 152: Precautions After Completion Of Work
14. COLD WEATHER OPERATION 14.2 PRECAUTIONS AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions. ‡ Mud and water on the machine body should be completely removed.
Page 153: Warming-Up Operation For Steering Hydraulic Circuit In Cold Weather
14. COLD WEATHER OPERATION 14.4 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER ¤ WARNING If the steering wheel is turned and stopped while the oil tem- perature is low, it may take some time for the vehicle to stop turning.
Page 154: Long-Term Storage
15.3 AFTER STORAGE NOTICE If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service. Carry out the following procedure when taking the machine out of long-term storage. ‡...
Page 155: Troubleshooting
16. TROUBLESHOOTING 16.1 WHEN MACHINE RUNS OUT OF FUEL WARNING The engine will start, so check carefully that the area around the engine is safe before cranking the engine. If the machine has run out of fuel, add fuel and then bleed the air from the fuel system before starting the engine.
Page 156: Towing The Machine
The machine must not be towed for long distances. ‡ For details of the procedure for towing a machine when it has broken down, please contact your Komatsu distributor. This machine must not be towed except in emergencies. When towing the machine, take the following precautions.
Page 157 16. TROUBLESHOOTING ‡ The towing machine should normally be of the same class as the machine being towed. Check that the towing machine has ample braking power, weight, and rimpull to allow it to control both machine on slopes or on the tow road. ‡...
Page 158 NOTICE Always request your Komatsu distributor to carry out the emergency travel operation, or consult your Komatsu distributor before carrying it out yourself. 2-108...
Page 159: If Battery Is Discharged
16. TROUBLESHOOTING 16.3 IF BATTERY IS DISCHARGED WARNING ‡ When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position before starting. ‡ Before starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the battery.
Page 160 16. TROUBLESHOOTING 16.3.2 PRECAUTIONS FOR CHARGING BATTERY CHARGING BATTERY WHEN MOUNTED ON MACHINE Before charging, disconnect the cable from the negative . ‡ terminal of the battery. Otherwise, an unusually high voltage will damage the alternator. ‡ While charging the battery, remove all battery plugs for satisfac- tory ventilation.
Page 161 16. TROUBLESHOOTING 16.3.3 STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING INCORRECT ‡ When connecting the cables, never contact the positive + and negative . terminals. ‡...
Page 162 16. TROUBLESHOOTING CONNECTING THE BOOSTER CABLES Keep the starting switch at the OFF position. Connect the booster cable as follows, in the order of the num- bers marked in the diagram. 1. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position.
Page 163: Other Trouble
16.4 OTHER TROUBLE 16.4.1 ELECTRICAL SYSTEM ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even ‡...
Page 164 16. TROUBLESHOOTING 16.4.2 CHASSIS ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Transmission Engine is running but machine ‡...
Page 165 16. TROUBLESHOOTING CHASSIS continued (16.4.2) Problem Main causes Remedy Brake Brake is not applied when pedal ‡ Disc has reached wear limit (‡ Replace disc) is depressed ‡ Defective hydraulic system ﬁ Lack of oil ﬁ Add oil to specified level. See CHECK BEFORE STARTING ‡...
Page 166 16. TROUBLESHOOTING CHASSIS continued (16.4.2) Problem Main causes Remedy Hydraulic system Lack of lifting power for bucket ‡ Lack of oil ‡ Add oil to specified level. See EVERY 100 HOURS SERVICE Bucket takes time to rise ‡ Clogged hydraulic tank filter ‡...
Page 167 16. TROUBLESHOOTING 16.4.3 ENGINE ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure caution pilot ‡...
Page 168 16. TROUBLESHOOTING ENGINE continued (16.4.3) Problem Main causes Remedy Exhaust gas occasionally turns ‡ Clogged air cleaner element ‡ Clean or replace, see WHEN black REQUIRED ‡ Defective nozzle (‡ Replace nozzle) ‡ Defective compression (‡ See defective compression above) ‡...
Page 169 16.4.4 APS (automatic priming system) ‡ ): Always contact your Komatsu distributor when dealing with these items. ‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine does not start at all ‡...
Page 170 MEMO 2-120...
Page 171 MAINTENANCE...
Page 172 17. GUIDES TO MAINTENANCE Do not carry out any inspection and maintenance operation that is not given in this manual. Perform maintenance work on hard, flat ground. Set to the inspection and maintenance posture. Always carry out operations with the machine in the following posture unless otherwise specified.
Page 173 Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu genuine oils: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Always use clean washer fluid: Use automobile window washer fluid and be careful not to let any dirt get into it.
Page 174 The rod end should be greased only when it becomes stiff after using it for long span of time. Controller: The controller for the machine monitor may be mistakenly actuated by interference from external electric waves. For this reason, when installing a radio or other such device, please consult your Komatsu distributor.
Page 175 When changing the oil, always replace the related filters at the same time. ‡ We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor.
Page 176 When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual. ‡ Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system.
Page 177 ‡ When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, please contact your Komatsu distributor. ‡ Do not open packs of spare filters until just before they are to be used.
Page 178 Never remove or disassemble any electric components installed in the machine. ‡ Never install any electric components other than those specified by Komatsu. ‡ Be careful to keep the electric system free of water when washing the machine or when it rains.
Page 179 The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book.
Page 180 – 44.0 UK gal ª ASTM D975 No. 1 When operating the machine at temperatures below –20°C, other equipment is needed, so please consult your Komatsu distributor. Note 1: For axle oil, use only recommended oil as follows. SHELL: DONAX TT or TD...
Page 181 ‡ We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. Specified capacity: Total amount of oil including oil for components and oil in piping.
Page 182 (The 15W40 oil SAE80, 90, 140 NLGI No. 2 Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT (Winter, one EO15-40CD season type) Diesel sigma S Super dieselmulti- AGIP Rotra MP GR MU/EP –...
Page 183 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Engine Oil Anti-freeze [CD or CE] Coolant SAE10W, 30, 40 Gear Oil Grease Supplier [Ethylene Glycol 10W30, 15W40 [GL-4 or GL-5] [Lithium-Base] Base] (The 15W40 oil SAE80, 90, 140 NLGI No.
Page 184 Hose nozzle for grease pump Grease cartridge 07950-90403 (Lithium base grease: 400 g) Nipple 424-98-11110 For hydraulic oil drain Hose 424-98-11120 Hammer 09039-00150 Plate 09963-03000 Warning tag If any of the above tools are broken, please order them from your Komatsu distributor. 3-14...
Page 185 The tightening torque is determined by the width across the flats b of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 186 If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the safety critical parts. 3-16...
Page 187 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q’ty Replacement interval Fuel spill hose (between nozzles) Turbocharger lubricating hose Fuel hose (nozzle – fuel return hose) Fuel hose (for APS) Fuel hose (fuel tank – strainer) Fuel hose (strainer –...
Page 188 23. MAINTENANCE SCHEDULE CHART 23.1 MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE INITIAL 250 HOURS SERVICE (only after the first 250 hours) Replace fuel filter cartridge 3-22 Replace transmission oil filter element 3-22 Check engine valve clearance, adjust 3-22 WHEN REQUIRED Check, clean, or replace air cleaner element 3-23 Clean inside of cooling system...
Page 189 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE CHECK BEFORE STARTING Check monitor panel 3-45 Check coolant level, add water 3-45 Check oil level in engine oil pan, add oil 3-46 Check brake oil tank level, add oil 3-47 Check fuel level, add fuel 3-48 Check electric wiring 3-49...
Page 190 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE EVERY 100 HOURS SERVICE (continued) ‡ Tilt lever pin (1 point) 3-55 ‡ Front axle support pin (1 point) 3-55 ‡ Rear axle support pin (1 point) 3-55 ‡ Rear axle support pin cover (1 point) 3-55 Check oil level in hydraulic tank, add oil 3-56...
Page 191 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE EVERY 1000 HOURS SERVICE (continued) ‡ Parking brake linkage (6 points) 3-71 ‡ Fan pulley (1 point) 3-71 ‡ Tension pulley (2 points) 3-71 Check tightening parts of turbocharger 3-72 Clean fuel strainer 3-72 Tighten ROPS canopy 3-72...
Page 192 24. SERVICE PROCEDURE 24.1 INITIAL 250 HOURS SERVICE WARNING Be sure to put a warning tag on work equipment control levers 1. Carry out the following maintenance only after the first 250 hours. ‡ REPLACE FUEL FILTER CARTRIDGE ‡ REPLACE TRANSMISSION OIL FILTER ELEMENT ‡...
Page 193 24. SERVICE PROCEDURE 24.2 WHEN REQUIRED WARNING Be sure to put a warning tag on work equipment control levers 1. 24.2.1 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT WARNING ‡ Never clean or replace the air cleaner element with the engine running.
Page 194 24. SERVICE PROCEDURE NOTICE If small holes or thinner parts are found on element when it is checked with an electric bulb after cleaning and drying, replace the element. When cleaning the element, do not hit it or beat it against anything.
Page 195 24. SERVICE PROCEDURE 24.2.2 CLEAN INSIDE OF COOLING SYSTEM WARNING ‡ Soon after the engine has been stopped, the coolant is hot and can cause personal injury. Allow the engine to cool before draining water. ‡ Since cleaning is performed while the engine is running, it is very dangerous to go under the machine as the machine may suddenly start moving.
Page 196 Antifreeze is flammable, so keep it away from any flame. ‡ Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. ‡ We recommend use of an antifreeze density gauge to control the mixing proportions.
Page 197 24. SERVICE PROCEDURE 1. Stop the engine and tighten corrosion resistor valve 1. 2. When removing radiator cap 2, lift the lever to relieve the internal pressure. Turn radiator cap 2 slowly to remove it. 3. Prepare a container to catch the coolant, then open drain valve 3 of the radiator and drain plug 4 at the side of the cylinder block and plug 5 on the side of torque converter cooler to drain the coolant.
Page 198 24. SERVICE PROCEDURE 9. When the water comes up to near the water filler port, open drain valve 3, drain plugs 4 and 5, run the engine at low idling, and continue to run water through the system until clean colorless water comes out.
Page 199 24. SERVICE PROCEDURE 24.2.3 CHECK TRANSMISSION OIL LEVEL, ADD OIL WARNING ‡ When checking the oil level, apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ The oil is at high temperature after the machine has been operated.
Page 200 24. SERVICE PROCEDURE 24.2.4 CHECK AXLE OIL LEVEL, ADD OIL WARNING ‡ When checking the oil level, apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ The oil is at high temperature after the machine has been operated.
Page 201 24. SERVICE PROCEDURE 24.2.5 CHECK AXLE CASE BREATHER WARNING When cleaning, apply the parking brake, and lock the front and rear frames with the safety bar and pin. Remove any mud or dust that is stuck to the area around the breather.
Page 202 24. SERVICE PROCEDURE 24.2.7 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID Do this when there is air in the window washing fluid. Check the washing fluid levels in washer tanks 1 and 2. When the fluid has run short, add automotive window washing fluid. 1: Front window washing fluid tank 2: Rear window washing fluid tank To prevent the nozzles from clogging, be careful not to let dust...
Page 203 24. SERVICE PROCEDURE 24.2.9 CHECK APS (automatic priming system) Check APS when the ambient temperature drops to 15°C. 1. Open fuel valve 1 of automatic priming system, and remove hose 2 at entrance of nozzle. 2. Move feed pump 3 up and down, and bleed air until air bubbles stop coming out of opening of hose 2.
Page 204 24. SERVICE PROCEDURE 24.2.10 REPLACE BUCKET TEETH WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine, apply the parking brake and locks securely to the work equipment control levers.
Page 205 24. SERVICE PROCEDURE 24.2.11 LUBRICATING WARNING ‡ Apply the parking brake switch, and lock the front and rear frames with the safety bar and pin. ‡ Set the work equipment in a stable condition, then stop the engine and locks the work equipment control levers with the safety lock lever.
Page 206 At the same time, inspect the flow of refrigerant gas (R134a) through the sight glass to check the gas level. Please contact your Komatsu distributor for this inspection. The sight glass is installed to the receiver on the right side of the air cleaner.
Page 207 3. Check the lining for wear and replace the pad if the thickness of the lining is reduced to less than 3 mm (0.12 in). Ask your Komatsu distributor for replacement of the pad. 3-37...
Page 208 Bleed the air at all 4 locations. After bleeding the air, check the oil level in the brake oil tank. For details, contact your Komatsu distributor. 24.2.15 BLEEDING AIR FROM PPC CIRCUIT When removing piping of PPC circuit, or removing strainer, after...
Page 209 24. SERVICE PROCEDURE 24.2.16 REPLACE SLOW BLOW FUSE NOTICE ‡ Always turn the power OFF when replacing the slow blow fuse (turn the starting switch to the OFF position). ‡ Always replace the slow blow fuse with a fuse of the same capacity.
Page 210 3. Continue until oil flows out from plug 1 (2 places) and the connector of hose 2. After the air has been completely bled, tighten plug 1 (2 places) and the connector of hose 2. 4. Check the oil level and add oil if necessary. For details, contact your Komatsu distributor. 3-40...
Page 211 24. SERVICE PROCEDURE Bleeding air from hydraulic circuit. 1. Check that the oil reaches the specified level in the hydraulic tank. 2. Run the engine at low idling and operate each hydraulic cylin- ders (of steering, bucket and lift arm) 4 to 5 times, stopping 100 mm (3.94 in) from stroke end.
Page 212 24. SERVICE PROCEDURE 24.2.18 REPLACE FAN BELT, ADJUST AUTO- TENSIONER Replace the V-belts if they contact the bottom of the pulley grooves or if they are lower than the outside diameter of the pulleys or if they are cracked or flaked. Replacement 1.
Page 213 Select the tires according to the conditions of use and attach- ments of the machine. Use the following table. Since the indicated speed varies with the tire size, consult your Komatsu distributor when using optional tires. Maximum load...
Page 214 24. SERVICE PROCEDURE CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM WARNING When inflating a tire, check that no one will enter the working area and use an air chuck which has a clip and which can be fixed to the air valve.
Page 215 3 seconds and the alarm buzzer sounds for about 1 second. If any monitor lamp does not light up, ask your Komatsu distribu- tor to inspect that monitor lamp. Do not carry out the checks before starting using only the monitor;...
Page 216 24. SERVICE PROCEDURE 24.3.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the inspection window at the rear right side of the ma- chine. 2. Remove dipstick G and wipe the oil off with a cloth. 3. Insert dipstick G fully in the oil filler pipe, then take it out again. 4.
Page 217 24. SERVICE PROCEDURE 24.3.4 CHECK BRAKE OIL TANK LEVEL, ADD OIL WARNING Always use engine oil to refill the brake oil tank. 1. Check from the ground that the brake oil level in the brake oil tank on the left side of the machine is within sight gauge 1 installed to the side of the brake tank.
Page 218 24. SERVICE PROCEDURE 24.3.5 CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If spilling fuel, thoroughly clean up any spillage. 1. Turn the engine starting switch to the ON position, then check the fuel level with fuel gauge G.
Page 219 When carrying out walk-around checks or checks before starting, always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of the cause. 24.3.7 CHECK INFLATION PRESSURE OF TIRES Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.
Page 220 24. SERVICE PROCEDURE 24.3.8 CHECK EFFECT OF PARKING BRAKE WARNING Even if the parking brake switch is turned ON, there is danger until the parking brake pilot lamp lights up, so keep the brake pedal depressed. Measurement conditions ‡ Tire inflation pressure: Specified pressure ‡...
Page 221 24. SERVICE PROCEDURE 24.3.16 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER (IF EQUIPPED) The water separator separates water mixed in the fuel. If float 2 is at or above red line 1, drain the water. For the draining procedure, see section “24.2 WHEN REQUIRED”. Even if a water separator is installed, be sure to check the fuel tank to remove water and sediment in the fuel.
Page 222 24. SERVICE PROCEDURE 24.4 EVERY 50 HOURS SERVICE WARNING Be sure to put a warning tag on work equipment control levers 24.4.1 DRAIN WATER, SEDIMENT FROM FUEL TANK Loosen valve 1 on the right side of the tank so that the sediment and water will be drained together with fuel.
Page 227 4. Loosen drain valve P, and drain the oil. 5. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 6. Install drain valve P. 7. Using the filter wrench, turn 2 filter cartridges 1 and bypass filter cartridge 2 to the counterclockwise to remove it.
Page 228 24. SERVICE PROCEDURE 8. Clean the filter holder, fill the new filter cartridge with engine oil, then coat the seal and thread of the filter cartridge with engine oil (or coat thinly with grease) and install. 9. When installing, bring the seal surface into contact with the filter holder, then tighten a further 3/4 –...
Page 229 24. SERVICE PROCEDURE 24.6.2 CHECK BATTERY ELECTROLYTE LEVEL WARNING ‡ To avoid gas explosions, do not bring fire or sparks near the battery. ‡ Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor.
Page 230 24. SERVICE PROCEDURE 24.6.3 CHECK ALTERNATOR BELT TENSION, ADJUST Checking The standard deflection for the drive belt is about 15 mm (0.6 in) when pressed by thumb 58.8N (about 6 kgf) at a point midway between the drive pulley and alternator pulley. Adjusting 1.
Page 231 24. SERVICE PROCEDURE 24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (if equipped) Checking The belt should normally deflect by about 10 mm (0.4 in) when pressed with the finger (with a force of approx. 58.8 N (6 kgf)) at a point midway between the drive pulley and compressor pulley.
Page 232 2. Check all parts of the frame and boom for damage. In particular, check the colored part in the diagram, and repair if any cracks or other damage are found. For details of the method of repair, please contact your Komatsu distributor. 3-62...
Page 233 24. SERVICE PROCEDURE 24.7 EVERY 500 HOURS SERVICE WARNING Be sure to put a warning tag on work equipment control levers Maintenance for every 50, 100 and 250 hours should be carried out at the same time. 24.7.1 REPLACE FUEL FILTER CARTRIDGE WARNING ‡...
Page 234 24. SERVICE PROCEDURE WARNING When cranking the engine, confirm the safety around the en- gine, as the engine may start. 11. After replacing the filter cartridge, turn the key in the starting switch to the START position. When the engine starts, check for any leakage from the filter seal surface.
Page 235 24. SERVICE PROCEDURE 24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT WARNING ‡ Apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before carrying out maintenance.
Page 236 24. SERVICE PROCEDURE 24.7.3 LUBRICATE CENTER DRIVE SHAFT (3 points) WARNING ‡ Apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.
Page 237 24. SERVICE PROCEDURE 24.7.4 CHECK FAN BELT FOR WEAR Check the V-belt and when the following conditions exist, re- place or adjust the V-belt. ‡ When there is a gap between the tension pulley lever and tip of the adjustment screw. ‡...
Page 238 24. SERVICE PROCEDURE 24.8 EVERY 1000 HOURS SERVICE WARNING Be sure to put a warning tag on work equipment control levers Maintenance for every 50, 100, 250 and 500 hours should be carried out at the same time. 24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER WARNING ‡...
Page 239 24. SERVICE PROCEDURE 5. Remove drain plug 7 (4 pieces) at the bottom of the filter case, and drain the oil. After draining the oil, tighten the plug. 6. Remove bolt 8, then remove cover 9 and take out strainer A together with spring 0.
Page 240 24. SERVICE PROCEDURE 24.8.3 LUBRICATING WARNING ‡ Apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.
Page 241 24. SERVICE PROCEDURE 3. Rear drive shaft (2 points) 4. Upper drive shaft (3 points) 5. Front drive shaft (3 points) 6. Transmission mount trunnion (1 point) 7. Parking brake linkage (6 points) 8. Fan pulley (1 point) 9. Tension pulley (2 points) 3-71...
Page 242 24. SERVICE PROCEDURE 24.8.4 CHECK TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked. 24.8.5 CLEAN FUEL STRAINER 1. Remove plug 1, then remove spring together with strainer. 2. Remove all dirt from the surface of the strainer, then wash in clean light oil.
Page 243 24. SERVICE PROCEDURE 24.8.7 REPLACE CORROSION RESISTOR CARTRIDGE WARNING If the engine has been operated, all parts will be at a high temperature, so never try to replace the cartridge immediately after stopping the engine. Always wait for the engine and other parts to cool down. Prepare the following.
Page 244 24. SERVICE PROCEDURE 24.9 EVERY 2000 HOURS SERVICE WARNING Be sure to put a warning tag on work equipment control levers Maintenance for every 50, 100, 250, 500 and 1000 hours should be carried out at the same time. 24.9.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT WARNING The oil is at high temperature immediately after the machine...
Page 245 24. SERVICE PROCEDURE 8. Remove mounting bolts 5 of the 2 filter covers 4 at the top of the tank, then remove the covers. When doing this, the cover may fly off because of the force of spring 6, so keep the cover pushed down while removing the bolts.
Page 246 24. SERVICE PROCEDURE NOTICE Never start the engine before the air has been completely bled from the piston pump. If the engine is started without the air being bled from the piston pump, the piston pump may be broken. 18. Check the oil level and add oil through oil filler port F if necessary.
Page 247 24. SERVICE PROCEDURE 24.9.2 CLEAN HYDRAULIC TANK STRAINER When changing the oil in the hydraulic tank, drain the oil from the tank and clean the strainer. 1. Loosen bolts 1 and 3, then remove covers 2 and 4. 2. Loosen bolt 5, remove strainer cover 6, then remove strainer 8 together with spring 7.
Page 248 24. SERVICE PROCEDURE 24.9.3 REPLACE HYDRAULIC TANK BREATHER ELEMENT WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before chang- ing the oil. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it carefully.
Page 249 24. SERVICE PROCEDURE 24.9.4 CHANGE AXLE OIL WARNING ‡ Apply the parking brake, and lock the front and rear frames with the safety bar and pin. ‡ Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the work equipment control levers.
Page 250 24. SERVICE PROCEDURE 3. Stop the machine so that drain plug 4 of the final drive is at the bottom. Remove oil filler plug 5 and drain plug 4, and fit the tube of attached tool in hole of plug 4 and drain the oil. 4.
Page 251 6. Bleed the air from the hydraulic circuit. For details, see “24.2.15 BLEEDING AIR FROM PPC CIRCUIT”. For details of the procedure for bleeding air from the hydraulic circuit, please contact your Komatsu distributor. 24.9.7 CLEAN ENGINE BREATHER ELEMENT WARNING Always wear safety glasses when using compressed air.
Page 252 If the work equipment stops moving during checking, the gas pressure may be below the service limit (0.69 MPa (7 kgf/cm , 99.4 PSI)), so contact your Komatsu distributor to have the gas pressure measured or gas charged. Carry out the checks within five minutes of stopping the engine.
Page 253 Komatsu distributor for repair. 24.10.3 CHECK FAN PULLEY AND TENSION PULLEY Check the pulley to see if there is any leaking grease. If any abnormality is found, ask your Komatsu distributor to repair or replace it. 24.10.4 REPLACE INJECTION PUMP SCREEN FILTER Remove injection pump cap 1, then replace screen filter 2 with a new part.
Page 254 MEMO 3-84...
Page 255 SPECIFICATIONS...
Page 256 WEIGHT ‡ Operating weight (including 1 operator: 80 kg (176 lb)) 70800 kg (156090 lb) ENGINE ‡ Model Komatsu SAA6D170-E diesel engine ‡ Flywheel horsepower 478 kW (641 HP)/2000 rpm ‡ Max. torque 2810 N·m (286.5 kgf·m)/1400 rpm ‡ Starting motor 24 V 7.5 kW x 2 pieces...
Page 257 25. SPECIFICATIONS...
Page 258 MEMO...
Page 259 OPTIONS, ATTACHMENTS...
Page 260 ‡ Tip type tooth for limestone Mesh chain Tire protector ‡ Air conditioner ‡ Car radio ‡ Auto grease system ‡ Auto shift ‡ Joy stick steering system ‡ Tires These and various other parts and attachments are available, so please contact your Komatsu distributor.
Page 261 Soft ground The speed display differs according to the tire size, so when chang- ing to optional tires, please contact your Komatsu distributor. On jobistes where there are many boulders or sharp rocks, please install tire protectors (mesh chain).
Page 262 28. HANDLING AUTO SHIFT SYSTEM 28.1 AUTOMATIC SHIFT SYSTEM 28.1.1 METHOD OF OPERATING Automatic gear shifting can be carried out in the 2nd to 4th speed range of the four forward and reverse speeds depending on the travel conditions. Position 1: 1st speed Position 2: 2nd speed Position 3: 3rd speed Position 4: 4th speed...
Page 263 28. HANDLING AUTO SHIFT SYSTEM 28.2 PRECAUTIONS WHEN CHANGING DIRECTION WARNING ‡ When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so be particularly careful when changing direction to travel in reverse.
Page 264 29. HANDLING JOYSTICK STEERING SYSTEM To ensure that you operate the joystick steering safely and efficiently, please read this section before using it. 29.1 EXPLANATION OF COMPONENTS 1. Joystick: Converts the displacement of the steering lever into voltage and controls steering according to the operation of the F-N-R button.
Page 265 29. HANDLING JOYSTICK STEERING SYSTEM 29.2 STRUCTURE AND FUNCTION OF JOYSTICK STEERING If the joystick ON/OFF switch is turned ON, electric current flows to the joystick controller and makes it possible to operate the steering with the joystick. In addition, the directional (forward or reverse) operation of the transmission can also be carried out from the directional lever by operating the F-N-R button on the top of the joystick.
Page 266 29. HANDLING JOYSTICK STEERING SYSTEM 1) Change the transmission to the manual mode (ON/OFF) with the manual switch (push-button switch). When the switch is pressed once, the pilot lamp lights up and the system is turned ON; when the switch is pressed again, the pilot lamp goes out and the system is switched OFF.
Page 267 29. HANDLING JOYSTICK STEERING SYSTEM 2. Work with joystick and steering wheel ¤ CAUTION Because of the neutral interlock circuit, the forward and reverse directions of the transmission cannot be changed over (from forward/reverse lever to F/N/R button of the joystick when the joystick ON/OFF switch is on, and from F/N/R button of the joystick to forward/reverse lever when the joystick ON/OFF switch is off) if the forward/reverse lever and F/N/R button of...
Page 268 29. HANDLING JOYSTICK STEERING SYSTEM 29.3 OPERATION METHOD OF JOYSTICK STEERING SYSTEM ¤ CAUTION When operation with joystick lever 1, always adjust the angle of the steering wheel so that it is possible to see the F-N-R display (LED) on the left of the machine monitor. The illuminance of the LED changes as the small lamp is turned ON and OFF.
Page 269 29. HANDLING JOYSTICK STEERING SYSTEM 6. If joystick lever 1 is turned to the right, the vehicle turns to the right, and if the joystick lever is turned to the left, the vehicle turns to the left. The more sharply the joystick is turned, the more quickly the vehicle turns.
Page 270 ‡ Before starting the operation of the vehicle again, find out and repair the troubled part and confirm that the function is normal. For the troubleshooting and repair, please contact your Komatsu distributor. ‡ Never operate the vehicle before it is repaired completely. ‡...
Page 271 29. HANDLING JOYSTICK STEERING SYSTEM 29.5 ADJUSTMENT OF JOYSTICK CONSOLE ¤ WARNING ‡ When adjusting, park the vehicle on a level and safe place. ‡ Adjust before starting operation or when the operator changed. ‡ Before adjusting the console, adjust the operator's seat so that the operator can press the brake pedal fully with his back fitted to the seat back.
Page 272 29. HANDLING JOYSTICK STEERING SYSTEM 29.6 ADJUSTMENT OPERATOR’S SEAT 29.6.1 ADJUSTMENT OF SEAT ¤ WARNING ‡ Park the machine in a safe place and stop the engine when carrying out adjustment of the operator’s seat. ‡ Adjust the seat before starting operations or when changing operators.
Page 273 29. HANDLING JOYSTICK STEERING SYSTEM F: Adjusting height of headrest Move the headrest up and down to the desired height. The adjustment range is 50 mm (2.0 in). G: Adjusting headrest angle Rotate the headrest to the front or rear. H: Adjusting angle of armrest Adjust the angle of the armrest by rotating knob 5.
Page 274 30. MAIN MONITOR FAILURE DISPLAY If an error code is displayed on the main monitor portion (normally the speedometer display) of the machine monitor, follow the corresponding table when carrying out the selfdiagnostic troubleshooting below. 30.1 MAIN MONITOR FAILURE DISPLAY (Contents of operator’s actions against each error code) Option Transion...
Page 275 30. MAIN MONITOR FAILURE DISPLAY 30.2 ERROR CODES LIST INDICATED ON MAIN MONITOR TRANSMISSION CONTROL SYSTEM Auto/manual transmission control system Problem system Error Code Item Short circuit Disconnection Back-up lamp relay ﬁ ﬁ None – – F Sol. ﬁ ﬁ R Sol.
Page 276 30. MAIN MONITOR FAILURE DISPLAY JOYSTICK CONTROL SYSTEM (Including joystick unit and machine body harness system) Problem system Error Code Item Short circuit Disconnection Joystick caution relay ﬁ (*1) Steering R (right) Sol (Detected when power is ﬁ ﬁ output) Steering L (left) Sol (Detected when power is ﬁ...
Page 277 This does not indicate trouble. If the lamp does not stop flashing (does not light up), there is trouble with the machine. In such cases, stop the machine immediately and consult your Komatsu distributor. 5-19...
Page 278 31. HANDLING AUTO-GREASING SYSTEM 31.1 METHOD OF OPERATING AUTO-GREASING SYSTEM 1. If the starting switch of the vehicle is turned ON, this system automatically starts the operation. 2. Auto-greasing switch 1 If the auto-greasing switch 1 is pressed, the grease pump is operated, regardless of the time count.
Page 279 31. HANDLING AUTO-GREASING SYSTEM 3. Method of bleeding air from pressure switch This work shall be performed by two persons. 1) Open transmission inspection cover 5 at the rear of the cab. One person removes pressure switch 7 from block 6, then stays there.
Page 280 31. HANDLING AUTO-GREASING SYSTEM 6. Check of supply line pressure Check grease pump pressure gauge B and supply grease line pressure gauge C. Supply grease line pressure gauge Normal value: 20.6 MPa (210 kgf/cm , 2982 PSI) Grease pump pressure gauge Normal value: 2.06 MPa (21 kgf/cm , 298.2 PSI) 7.
Page 281 31. HANDLING AUTO-GREASING SYSTEM 8. Adjustment of greasing rate and injector ‡ Adjust the injector to change the greasing rate for 0 – 30 hours (First step), 30 – 150 hours (Second step) and after 150 hours after the auto-greasing system installed. ‡...
Page 282 31. HANDLING AUTO-GREASING SYSTEM Greasing points (Front frame and loader linkage) 1. Bucket hinge 2. Bucket link (front) 3. Bucket link (rear) 4. Bucket cylinder rod 6. Tilt lever (center) 7. Lift arm cylinder rod 5-24...
Page 283 31. HANDLING AUTO-GREASING SYSTEM Greasing points (Rear frame) 5. Bucket cylinder bottom 8. Lift arm cylinder bottom 9. Lift arm pivot 10. Center hinge pin (upper) 11. Steering cylinder bottom 12. Center support 13. Center hinge pin (lower) 14. Rear axle support (front) 15.
Page 284 31. HANDLING AUTO-GREASING SYSTEM 31.3 METHOD OF ADJUSTING DISCHARGE FROM INJECTOR 1. Injector (SL1) 1) The injector is operated by the pressure from the pump, and it feeds grease of the specified quantity to the bearing. 2) To see if the injector works normally, check the operation of indicator pin 1 on its head.
Page 285 31. HANDLING AUTO-GREASING SYSTEM 31.4 METHOD OF SETTING TIMER ‡ The timer is installed to control the greasing interval of the auto- grease system. ‡ The timer is installed in box 1 at the rear of the operator’s seat. ‡ The greasing interval can be changed freely according to the following table with the blue dial of the timer.
Page 286 31. HANDLING AUTO-GREASING SYSTEM 3. Method of adjusting operating time (Red dial) To adjust the operating time, turn red rotary switch 1 in the figure at right according to the following table. (Normally, fix this dial to position 8 (60 seconds).) Position of switch Operating time of pump (sec) 22.5...

Komatsu AVANCE LOADER WA700-3 Operation And Maintenance Manual

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