Page 2 1 - 1...
Page 3: Foreword
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy. When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
Page 4 FOREWORD FOREWORD 1 - 3...
Page 5 FOREWORD FOREWORD 1 - 4...
Page 6: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 8: Introduction
FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: Digging work Smoothing Pushing work Loading work For details of the operating procedure, see "WORK POSSIBLE USING WHEEL LOADER (PAGE 3-98)". FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the operator's seat in the direction of travel (front) of the machine.
Page 9: Necessary Information
FOREWORD NECESSARY INFORMATION NECESSARY INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE On the center right of the front frame. The design of the nameplate differs according to the territory.
Page 10: Position Of Service Meter
FOREWORD NECESSARY INFORMATION POSITION OF SERVICE METER It is at the center bottom of the machine monitor. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel Phone/Fax 1 - 9...
Page 11: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE NECESSARY INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NO. PLATE POSITION OF SERVICE METER TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SAFETY SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS...
Page 12 RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 11 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 12 TORQUE LIST...
Page 13 FOREWORD CONTENTS WHEN REQUIRED 4- 17 CHECK BEFORE STARTING 4- 35 EVERY 50 HOURS SERVICE 4- 36 EVERY 100 HOURS SERVICE 4- 37 EVERY 250 HOURS SERVICE 4- 39 EVERY 500 HOURS SERVICE 4- 45 EVERY 1000 HOURS SERVICE 4- 48 EVERY 2000 HOURS SERVICE 4- 52 EVERY 4000 HOURS SERVICE...
Page 14 2 - 1...
Page 15: Safety
SAFETY SAFETY SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS GENERAL PRECAUTION SAFETY RULES 2- 11 IF ABNORMALITIES ARE FOUND 2- 11 CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 11 FIRE EXTINGUISHER AND FIRST AID KIT 2- 11 SAFETY FEATURES 2- 11 KEEP MACHINE CLEAN 2- 12...
Page 16 SAFETY SAFETY PRECAUTIONS FOR OPERATION 2- 20 STARTING ENGINE 2- 20 CHECKS BEFORE STARTING ENGINE 2- 20 PRECAUTIONS WHEN STARTING 2- 20 PRECAUTIONS IN COLD AREAS 2- 21 OPERATION 2- 22 CHECKS BEFORE OPERATION 2- 22 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 22 PRECAUTIONS WHEN TRAVELING 2- 23...
Page 17 SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE 2- 32 WARNING TAG 2- 32 KEEP WORK PLACE CLEAN AND TIDY 2- 32 APPOINT LEADER WHEN WORKING WITH OTHERS 2- 32 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE 2- 33 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 34 INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S.
Page 18: Safety Labels
If the safety labels are damaged or lost, or cannot be read, replace them with new parts. For details of the part numbers, see this manual or check on the actual part, and order the new part from your Komatsu distributor.
Page 19: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before starting (09651-03001) (2) Caution for leaving the operator's seat (09654-03001) (3) Caution when traveling in reverse Please request part number 418-93-22273 for this safety label. 2 - 6...
Page 20 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Caution for going close to electric cables (09801-13001) (5) Do not enter (09162-23000) (6) Caution for frame lock bar (09161-23000) (7) Caution when coolant is at high temperature (09668-03001) 2 - 7...
Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (8) Caution when oil is at high temperature (09653-03001) (9) Caution when handling battery cable (09808-03000) (10) High pressure warning (09659-53000) (11) Do not climb on fender (09805-03000) (Machine equipped with rear fender) (12) "Do not open when engine is running" sign (09667-03001) 2 - 8...
Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (13) Caution to prevent entry of ether (421-93-A1510) (14) "Do not come near machine" sign (09812-13000) (15) "Do not go under work equipment" sign (09807-C0883) (16) "Do not modify ROPS" sign (09620-30201) 2 - 9...
Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (17) Jump start prohibited (09842-A0481) 2 - 10...
Page 24: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
Page 25: Keep Machine Clean
SAFETY GENERAL PRECAUTIONS KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors). If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes.
Page 26: Handrails And Steps
SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine. To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps to ensure that you support...
Page 27: Mounting And Dismounting
SAFETY GENERAL PRECAUTIONS MOUNTING AND DISMOUNTING Never jump on or off the machine. Never get on or off a moving machine. If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.
Page 28: Fire Prevention
SAFETY GENERAL PRECAUTIONS FIRE PREVENTION Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous. To prevent fire, always observe the following: Do not smoke or use any flame near fuel or oil. Stop the engine before refueling.
Page 29: Action If Fire Occurs
Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.
Page 30: Safety At Worksite
SAFETY GENERAL PRECAUTIONS SAFETY AT WORKSITE Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating. Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Page 31: Ensure Good Visibility
SAFETY SAFETY SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS GENERAL PRECAUTIONS Even going close to high-voltage cables can cause electric Voltage of Cables Safety Distance shock, which may cause serious burns or even death. Always 100 V - 200 V Over 2 m (7 ft) maintain a safe distance (see the table on the right) between the 6,600 V Over 2 m (7 ft)
Page 32: Be Careful About Asbestos Dust
Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 19...
Page 33: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment control lever, do not start the engine or touch the levers . CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.
Page 34: Precautions In Cold Areas
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS IN COLD AREAS Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
Page 35: Operation
SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS BEFORE OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check the operation of travel, steering and brake systems, and work equipment control system.
Page 36: Precautions When Traveling
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. 2 - 23...
Page 37: Traveling On Slopes
SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. When traveling on slopes, keep the bucket at height "A" of approximately 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, quickly lower the bucket to the ground to help the machine to stop.
Page 38: Prohibited Operations
SAFETY PRECAUTIONS FOR OPERATION PROHIBITED OPERATIONS It is dangerous to excavate the bottom of a rock face. Never do this. It is dangerous to use the bucket or lift arm for crane operations, so do not carry out such operations. Do not pass the bucket over the head of other workers or over the operator's seat of dump trucks or other hauling equipment.
Page 39: Methods Of Using Brake
SAFETY SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION When handling unstable loads, such as round or cylindrical objects, or piled sheets, if the work equipment is raised high, there is danger that the load may fall on top of the operator' compartment and cause serious injury or damage.
Page 40: Parking Machine
SAFETY PRECAUTIONS FOR OPERATION PARKING MACHINE Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground. When leaving the machine, set work equipment lock lever (1) to the LOCK position, pull parking brake lever (2) to the LOCK position, then stop the engine.
Page 41: Transportation
PRECAUTIONS FOR OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 42: Battery
SAFETY PRECAUTIONS FOR OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 43: Starting With Booster Cables
SAFETY PRECAUTIONS FOR OPERATION STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).
Page 44: Towing
SAFETY PRECAUTIONS FOR OPERATION TOWING WHEN TOWING Serious injury or death could result if there is any mistake in the selection of wire rope or method of towing a disabled machine. For towing, see "METHOD OF TOWING MACHINE (PAGE 3-124)". Always be sure to check carefully that the capacity of the wire rope used for towing is ample for the weight of the towed machine.
Page 45: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG Always attach the "DO NOT OPERATE" warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.
Page 46: Stop Engine Before Carrying Out Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground and stop the engine.
Page 47: Two Workers For Maintenance When Engine Is Running
SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE Lock the front and rear frames with frame lock bar (4). TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.
Page 48: Proper Tools
Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. PERSONNEL Only authorized personnel can service and repair the machine.
Page 49: Work Under The Machine
SAFETY PRECAUTIONS FOR MAINTENANCE WORK UNDER THE MACHINE When carrying out inspection and maintenance with the work equipment raised, use strong support (1) that can fully withstand the weight of the work equipment, and be sure to fix the stands in position securely.
Page 50: Precautions With High-Pressure Oil
If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 51: Compressed Air
SAFETY PRECAUTIONS FOR MAINTENANCE COMPRESSED AIR When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves, and other protective equipment.
Page 52: Precautions With Tires
Komatsu distributor to carry out these operations. Always use the tires specified by Komatsu and maintain the specified inflation pressure. Suitable tire inflation pressure: see "HANDLING THE TIRES (PAGE 3-112)"...
Page 53 3 - 1...
Page 54: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Bucket Turn signal lamp Tilt lever Head lamp Front wheel (10) Lift cylinder Bucket cylinder (11) Lift arm Front working lamp (12) Rear working lamp ROPS cab (13) Rear combination lamp Rear wheel 3 - 2...
Page 55: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Parking brake lever (17) Variable shift control switch Rear wiper switch (18) Speed range selector switch Front wiper switch (19) Starting switch Front working lamp switch (20) E.C.S.S. (electronic controlled suspension Rear working lamp switch system) switch (if equipped) Hazard lamp switch...
Page 56 OPERATION GENERAL VIEW MACHINE MONITOR Pilot lamp for speed range selector switch position (12) Parking brake pilot lamp Steering oil pressure caution lamp (13) Brake oil pressure caution lamp (Machines equipped with Emergency steering) (14) Parking brake reminder caution lamp Emergency steering pilot lamp (15) Axle oil temperature caution lamp...
Page 57: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MACHINE MONITOR Character display portion Pilot display portion...
Page 58 Lamps (2) and (3) stay on until the engine starts. If any lamps do not light up there is probably a failure or a disconnection. Ask your Komatsu distributor to diagnose the problem. Lamp (3) lights up only for the emergency steering device.
Page 59 OPERATION EXPLANATION OF COMPONENTS TYPES OF WARNING If an abnormality occurs on the machine, or if any switch or lever is operated accidently, the monitor display and buzzer give a warning to inform the operator. Following are the types of warning depending on the level of danger.
Page 60 When the starting switch is at the OFF position, if the service meter is displayed even though the top (") of monitor panel mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please contact your Komatsu distributor for inspection.
Page 61 If action code E03 is displayed, stop the machine immediately and check the failure code. For details, see "FAILURE CODE DISPLAY (PAGE 3-11)". Inform your Komatsu distributor of the failure code and ask for repairs. If there is a failure on the machine, if it is necessary to change the method of operation, or if inspection or maintenance must be carried out, action code E00, E01, E02, or E03 is displayed on the character display in display portion (2).
Page 62 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS E01: When a failure occurs in the mechanical system, such as a drop in the level of the engine coolant, the maintenance location is displayed. If the maintenance caution lamp lights up at the same time, inspect and perform maintenance of the item indicated after completion of the day's work or when changing shifts.
Page 63 If an action code is displayed on the character display, check the failure code according to the failure code display method given below. When contacting your Komatsu distributor to request repairs, inform your distributor of the failure code. Method of displaying failure code 1.
Page 64 OPERATION EXPLANATION OF COMPONENTS FILTER, OIL REPLACEMENT TIME DISPLAY After completion of the system check and when the starting switch is in the ON position, if any filter or oil item is approaching the replacement time, this display (4) shows the item for approx. 30 seconds.
Page 65 OPERATION EXPLANATION OF COMPONENTS REMARK See the section below for details of the procedure for replacing the filter and oil. Engine oil "CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-45)" Engine oil filter "CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-45)" Fuel filter "REPLACE FUEL FILTER CARTRIDGE (PAGE 4-46)"...
Page 66 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEMS CAUTION If these lamps light up and the buzzer sounds, stop operations immediately and carry out inspection and maintenance of the applicable location. If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the lamp for the location of the abnormality and the central warning lamp will light up.
Page 67: Steering Oil Pressure Caution Lamp
OPERATION EXPLANATION OF COMPONENTS ENGINE OIL PRESSURE CAUTION LAMP This lamp (2) lights up to warn the operator that the engine lubricating oil pressure has dropped. During checks before starting (starting switch at the ON position, engine stopped) the lamps are lighted up, and when the engine is started, the lamps go out.
Page 68 OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If these lamps light up, stop operations quickly and carry out the following action. Axle oil temperature caution lamp Engine coolant temperature caution lamp Parking brake reminder caution lamp Fuel level caution lamp HST oil temperature caution lamp AXLE OIL TEMPERATURE CAUTION LAMP This lamp (1) lights up to warn the operator that the brake oil...
Page 69 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE REMINDER CAUTION LAMP This lamp (2) lights up when the engine is stopped but the parking brake is not applied. At the same time, the central warning lamp lights up and the alarm buzzer sounds intermittently. When the parking brake is applied, the lamp goes out and the buzzer stops.
Page 70 OPERATION EXPLANATION OF COMPONENTS FUEL LEVEL CAUTION LAMP This monitor (5) lights up if the amount of fuel remaining in the fuel tank goes below 26 liters (6.87 US gal). If it lights up, check and add fuel as soon as possible. REMARK Even if the caution lamp lights up, action code "E02"...
Page 71 OPERATION EXPLANATION OF COMPONENTS WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED When the travel speed goes above 40.0 km/h (24.9 MPH), the central warning lamp lights up and the alarm buzzer sounds. At the same time, "E00" is displayed on the character display, and then "OVERRUN PROTECT"...
Page 72 OPERATION EXPLANATION OF COMPONENTS INSPECTION AND MAINTENANCE ITEMS CAUTION If these lamps light up, stop operations quickly and carry out the following action. Radiator coolant level caution lamp HST oil filter clogging caution lamp Maintenance caution lamp RADIATOR COOLANT LEVEL CAUTION LAMP This lamp (1) lights up to warn the operator that the coolant level in the radiator has gone down.
Page 73 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE CAUTION LAMP CAUTION If the caution lamp lights up, repair the problem as soon as possible. If this is left as it is, it will lead to failure. When the time for filter and oil change is reached, this lamp (2) flashes or lights up for approx.
Page 74: Emergency Steering Pilot Lamp
OPERATION EXPLANATION OF COMPONENTS PILOT DISPLAY PORTION When the starting switch is ON, the pilot display lights up when the display items are functioning. Parking brake pilot lamp Directional lever position pilot lamp Preheating pilot lamp Pilot lamp for speed range selector switch position Emergency steering pilot lamp Turn signal pilot lamp (Machines equipped with Emergency steering)
Page 75: (Machines Equipped With Emergency Steering)
OPERATION EXPLANATION OF COMPONENTS EMERGENCY STEERING PILOT LAMP (Green) (Machines equipped with Emergency steering) If this lamp (3) lights up when the engine is running or when the machine is operating, it indicates that the condition is normal. If it does not light up, an abnormality has occurred in the emergency steering circuit.
Page 76: Head Lamp High Beam Pilot Lamp
OPERATION EXPLANATION OF COMPONENTS HEAD LAMP HIGH BEAM PILOT LAMP This lamp (7) lights up when the head lamp is at high beam. 3 - 24...
Page 77 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION HST oil temperature gauge Speedometer Engine coolant temperature gauge Meter display pilot lamp Fuel gauge HST OIL TEMPERATURE GAUGE This meter (1) indicates the HST oil temperature. During normal operations, the indicator should be in the white range (A).
Page 78 OPERATION EXPLANATION OF COMPONENTS FUEL GAUGE This meter (3) indicates the amount of fuel remaining in the fuel tank. If the indicator is at the F position, it indicates that the tank is full. If the indicator is at the E position, it indicates that there is little fuel remaining.
Page 79 OPERATION EXPLANATION OF COMPONENTS OTHER FUNCTIONS OF MACHINE MONITOR The machine monitor also has the following functions. Odometer, filter/oil replacement time reset, language selection, HST selector function METHOD OF DISPLAYING ODOMETER Use this when checking the total distance that the machine has traveled. 1.
Page 80 OPERATION EXPLANATION OF COMPONENTS RESET METHOD FOR FILTER, OIL REPLACEMENT TIME The filter and oil replacement time is displayed on the character display, so if the filter and oil have been replaced, reset the filter and oil change time. 1. Press the (") of monitor panel mode selector switch 1, and display the odometer. 2.
Page 81 OPERATION EXPLANATION OF COMPONENTS METHOD FOR SELECTING LANGUAGE Use this when switching the language displayed on the character display. The following explanation is for when English is set as the language for the character display. 1. Press the (") of monitor panel mode selector switch 1, and display the odometer. 2.
Page 82 OPERATION EXPLANATION OF COMPONENTS METHOD OF SELECTING HST CHANGING FUNCTION When the speed range selector switch is in 3rd or 4th position, there are two selections available for the HST. Use this when changing the selection. Speed range selector switch position Function 3rd position 4th position...
Page 83: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Starting switch (11) Front working lamp switch Speed range selector switch (12) Rear working lamp switch Variable shift control switch (13) Monitor panel mode selector switch 1 Directional selector switch (14) Monitor panel mode selector switch 2 Directional selector actuation switch (15) Front wiper switch...
Page 84 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch (1) is used to start or stop the engine. OFF position In this position, it is possible to insert or remove the starting switch key. All the electric system switches are off, and the engine will stop.
Page 85 OPERATION EXPLANATION OF COMPONENTS VARIABLE SHIFT CONTROL SWITCH When the speed range is in 1st, it is possible to use this dial (3) to set the maximum speed as desired. Turn the dial to the right to increase the setting; turn it to the left to decrease the setting.
Page 86 OPERATION EXPLANATION OF COMPONENTS TRACTION CONTROL SWITCH When the speed range selector switch is at 2nd or 4th, this switch (6) can be used to actuate the traction control and reduce the maximum rimpull. Position (a): ON Traction control is activated. Position (b): OFF Traction control is deactivated.
Page 87 OPERATION EXPLANATION OF COMPONENTS E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) SWITCH (If equipped) WARNING If the machine is traveling or the work equipment is raised, the moment the E.C.S.S. switch is turned ON, the work equipment will move. If operations are carried out with the E.C.S.S. switch at the ON position, the moment the E.C.S.S. switch is operated, the work equipment may move.
Page 88 OPERATION EXPLANATION OF COMPONENTS TURN SIGNAL LEVER This switch (8) is used to operate the turn signal lamp. Position (a): LEFT TURN (Push lever FORWARD) Position (b): OFF Position (c): RIGHT TURN (Pull lever BACK) REMARK When the lever is operated, the turn signal pilot lamp also flashes.
Page 89 OPERATION EXPLANATION OF COMPONENTS HAZARD LAMP SWITCH WARNING Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for other machine operators. This switch (10) is used in emergencies, such as when the machine breaks down and has to be parked on the road. Position (a): Direction indicator lamp and directional indicator pilot lamp flash, and pilot lamp (A) lights up at the same time...
Page 90 OPERATION EXPLANATION OF COMPONENTS REAR WORKING LAMP SWITCH WARNING Always turn the working lamp off before traveling on public roads. This switch (12) is used to light up the rear working lamp. Position (a): Working lamp and pilot lamp (A) light up Position (b): Working lamp goes out REMARK If the lamp switch is not at the ON position for the side clearance...
Page 91 OPERATION EXPLANATION OF COMPONENTS FRONT WIPER SWITCH When rotary switch (A) of this switch (15) is turned, the front wiper will move. If push button (B) is pressed, washer liquid will be sprayed out onto the front glass while the button is being pressed. Position (a): (OFF) Stop Position (b): (INT) Intermittent wiper Position (c): Low-speed wiper...
Page 92 OPERATION EXPLANATION OF COMPONENTS REAR HEATED WIRE GLASS SWITCH When this switch (19) is pressed, electric current flows through the heated wire glass at the rear and the mist is removed from the glass. Position (a): ON (removes mist from glass) Position (b): OFF ATTACHMENT SELECTION SWITCH This switch (20) switches the bucket positioner and fork positioner.
Page 93: Control Levers, Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS, PEDALS Directional lever Brake pedal work equipment lock lever Accelerator pedal Work equipment lever Parking brake lever Auxiliary control lever DIRECTIONAL LEVER This lever (1) is used to switch the direction of travel of the machine between forward and reverse.
Page 94 OPERATION EXPLANATION OF COMPONENTS WORK EQUIPMENT LOCK LEVER WARNING Before leaving the operator's seat, set the work equipment lock lever securely to the LOCK position. If the work equipment lock lever is not at the LOCK position, and work equipment control lever is touched by mistake, it may lead to a serious accident. If the work equipment lock lever is not placed securely at the LOCK position, the work equipment control lever may move, and this may lead to a serious accident or personal injury.
Page 95 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Position (e): TILT When the work equipment control lever is pulled further beyond the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position.
Page 96 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. This lever (7) operates the parking brake.
Page 97: Steering Tilt Lock Lever
OPERATION EXPLANATION OF COMPONENTS STEERING TILT LOCK LEVER WARNING Stop the machine before adjusting the tilt of the steering wheel. If this operation (adjustment) is carried out while the machine is moving, it may lead to a serious accident or personal injury. This lever allows the steering column to be tilted forward or backward.
Page 98: Frame Lock Bar
OPERATION EXPLANATION OF COMPONENTS METHOD OF OPENING AND CLOSING COVER WITH LOCK (ENGINE SIDE COVER) TO OPEN THE COVER 1. Insert the key into the key slot. 2. Turn the key counterclockwise and open the cover by pulling the cover grip. TO LOCK THE COVER 1.
Page 99: Towing Pin
OPERATION EXPLANATION OF COMPONENTS TOWING PIN 1. Align protrusion (1) in the towing pin with groove (2) in the counterweight, then insert the pin and turn it 180°. 2. To prevent the towing pin from turning, fold the handle of the towing pin and set it in position.
Page 100: Cab Door Open Lock
OPERATION EXPLANATION OF COMPONENTS CAB DOOR OPEN LOCK When getting in or out of the operator's compartment, or when operating with the door open, use this lock to hold the door in position. 1. Push the door against catch (1) to lock it in position. 2.
Page 101 OPERATION EXPLANATION OF COMPONENTS FUSE CAPACITY AND NAME OF CIRCUIT FUSE BOX A Fuse No.‚ Name of circuit capacity Starting switch Hazard warning flashing lamp HST control A Parking brake A Instrument panel Radio A, Room lamp Auxiliary pwr (Battery +24V) Head Lamp L.H.
Page 102: Slow Blow Fuse
OPERATION EXPLANATION OF COMPONENTS SLOW BLOW FUSE If the power does not come on when the starting switch is turned ON, the slow blow fuse may be blown. Check and replace it. The slow blow fuse is beside the engine on the left side of the machine.
Page 103: Am/Fm Radio-Cassette Stereo
OPERATION EXPLANATION OF COMPONENTS AM/FM RADIO-CASSETTE STEREO (If equipped) EXPLANATION OF COMPONENTS Power switch/volume Cassette door Auto-store/preset scan button Fast forward, rewind buttons Bass control knob (10) Preset buttons Treble control knob (11) Metal tape button Loudness button (12) Manual tuning buttons Time/radio display selector button (13) Seek tuning buttons...
Page 104 OPERATION EXPLANATION OF COMPONENTS POWER SWITCH/VOLUME Turn this knob (1) to the right until it clicks to turn the power on. Turn it further to increase the volume. AUTO-STORE/PRESET SCAN BUTTON Use this button (2) to actuate the preset scan and auto-store functions.
Page 105 OPERATION EXPLANATION OF COMPONENTS TREBLE CONTROL KNOB Turn this button (4) to the left to reduce the low tones; turn it to the right to emphasize the high tones. Direction (a): High tone reduced Direction (b): High tone emphasized LOUDNESS BUTTON This button (5) is used when playing at low volume.
Page 106 OPERATION EXPLANATION OF COMPONENTS TAPE EJECT BUTTON This button (7) is used to stop the tape and to eject the cassette. When this button is pressed, the tape is ejected and the radio plays. CASSETTE DOOR Set the cassette with the exposed portion of the tape on the right side and insert it through the cassette door (8).
Page 107 OPERATION EXPLANATION OF COMPONENTS METAL TAPE BUTTON (used also for preset button No. 5) This button (11) is used when playing a metal or chrome tape. This button is also used for preset button No. 5. When it is pressed, "MTL"...
Page 108 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS It is possible to preset 6 MW (AM) stations and 12 FM stations (FM1: 6 stations, FM2: 6 stations). REMARK If you are playing the cassette, press the tape eject button to stop the tape. METHOD OF AUTO PRESET 1.
Page 109 OPERATION EXPLANATION OF COMPONENTS LISTENING TO RADIO 1. Turn the starting switch ON, then turn power switch (1) ON. 2. Use band selector button (2) to select MW (AM), FM1 or FM2. 3. Select the station with the preset buttons (3). REMARK In case you do not promptly remember the number assigned to a certain preset station, press auto-store/preset scan button (4) for...
Page 110 If the sound cannot be heard, nothing is displayed, or any other problem occurs, turn off the power switch and ask your Komatsu distributor to make repairs without delay. Stow the antenna when traveling in places with low overhead clearance.
Page 111: Air Conditioner
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it possible to provide a pleasant working environment even on dusty jobsites. GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL Fan switch FRESH/RECIRC selector switch...
Page 112 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH This switch (2) is used to start or stop the cooling or dehumidifying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.
Page 113 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH The temperature can be adjusted with this switch (5) by pressing and holding the up or down button. The temperature level indicator lamps (A) light up to display the temperature of the air coming from the vents. The more blue lamps on, the lower the temperature is.
Page 114 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION Switch Air conditioner Temperature FRESH/RECIRC Mode selector Fan switch switch control switch selector switch switch Condition of use Rapid All blue RECIRC FACE Cooling More than half Normal HI - LO FRESH FACE are blue Dehumidifying, More than half...
Page 115 OPERATION EXPLANATION OF COMPONENTS COOL BOX When the cooling is being used, this can be used for keeping drinks and other things cool. When the heating is being used, it can be used to keep things warm. When using the box, open the vent grill (1). When not using the box, close the grill (1).
Page 116: Handling Cab Wiper
OPERATION EXPLANATION OF COMPONENTS HANDLING CAB WIPER PREVENTING DAMAGE TO WIPER ARM BRACKET NOTICE When angling the wiper arm (1) to the front, check that the wiper blade is hanging free. When angling the wiper arm (1) to the front, such as when wiping the glass clean, if the wiper arm (1) is angled with the wiper blade (2) locked to the arm (the bottom of the blade is caught on the arm), abnormal force is brought to bear on the mounting bracket and the...
Page 117: Operation
Remove any flammable materials from around the battery, engine, muffler, turbocharger, or other high temperature engine parts. Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu distributor.
Page 118 OPERATION OPERATION 9. Check for loose air cleaner mounting bolts. Check for the loose bolts. If loose, tighten them. 10. Check for loose battery terminals. Tighten any loose terminal. 11. Check for damage to the seat belt and mounting clamps. WARNING Even if there appears to be no abnormality with the seat belt, replace it once every three years.
Page 119 OPERATION OPERATION 13. Inspect 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 grooves of less than 15% of that of a new tire Tires with extreme uneven wear or with stepped-type wear Damage: Tires with damage that has reached the cords, or with cracks in the...
Page 120 OPERATION OPERATION CHECK BEFORE STARTING Always perform the procedures in this section before starting the engine each day. CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation.
Page 121 OPERATION OPERATION CHECK WATER SEPARATOR The water separator separates water mixed in the fuel. If float (1) goes above water drain line (2), drain the water as follows. 1. Loosen drain plug (3) and drain the accumulated water until the float (1) reaches the bottom.
Page 122 OPERATION OPERATION CHECK COOLANT LEVEL, ADD COOLANT WARNING Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in the sub-tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to check the coolant level in this condition, there is a hazard of burns.
Page 123 CHECK ELECTRIC WIRING CAUTION 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 and make the repair. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.
Page 124 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames near fuel because it is highly flammable and dangerous. NOTICE If the engine has run out of fuel and has stopped, it is necessary to operate the priming pump to bleed the air completely from the fuel line before starting the engine again.
Page 125 Komatsu distributor for adjustment. CHECK BRAKE PEDAL Drive the machine forward and check the effect of the brakes. If there is any problem in the actuation of the brakes, please contact your Komatsu distributor to have the brakes adjusted. 3 - 73...
Page 126 OPERATION OPERATION ADJUSTMENT SEAT ADJUSTMENT WARNING When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK position to prevent any accidental contact with the control levers. Always adjust the operator's seat before starting each operation or when the operators change shift. When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 127 OPERATION OPERATION (H) Adjusting headrest angle Rotate the headrest (6) to the front or rear. Adjustment range: 60 degrees (I) Adjusting armrest angle Armrest (7) can be operated by hand to spring up approx. 90 degrees (both left and right). In addition, dial (8) under the armrest can be operated by hand to make fine adjustments of the armrest in the up or down direction (left side only).
Page 128 OPERATION OPERATION (G) Adjusting headrest height Move the headrest (6) up or down. Amount of adjustment: 50 mm (2.0 in) (H) Adjusting headrest angle Rotate the headrest (6) to the front or rear. Adjustment range: 60 degrees (I) Adjusting armrest angle Armrest (7) can be operated by hand to spring up approx.
Page 129 OPERATION OPERATION ADJUST LEVER STAND ADJUST HEIGHT OF WRIST REST Loosen lock lever (2) and adjust the height of wrist rest (1). Amount of adjustment: 60 mm (2.4 in) REMARK Keep button (3) pressed and operate lock lever (2) to the FREE position.
Page 130 OPERATION OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING When starting the engine, check that the work equipment lock lever are placed securely at the LOCK position. If the work equipment control lever is touched by accident when the engine is started, the work equipment may move unexpectedly and cause serious injury or damage.
Page 131 3 seconds, and the alarm buzzer sounds for approx. 1 sec. If any monitor does not light up, there is probably a failure or disconnection. Contact your Komatsu distributor inspection. 3 - 79...
Page 132: Starting Engine
OPERATION OPERATION STARTING ENGINE WARNING Sit down in the operator's seat before starting the engine. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 133 OPERATION OPERATION OPERATION OPERATION 2. Depress accelerator pedal (3) lightly. 3. After the pre-heating pilot lamp (2) goes out, turn the key of starting switch (1) to the START position to start the engine. 4. After the engine starts, release the key in starting switch (1). The key will automatically return to the ON position.
Page 134: Operations And Checks After Starting Engine
BREAKING-IN THE MACHINE CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
Page 135 Run the engine under a light load until engine coolant temperature gauge (4) and HST oil temperature gauge (5) are in the white range. 6. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 83...
Page 136: Stopping Engine
OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine except for an emergency. In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop it.
Page 137: Moving The Machine (Directional, Speed), Stopping The Machine
OPERATION OPERATION MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE WARNING Always remove the frame lock bar for travel operations. If it is not removed, the steering wheel cannot be used for steering, and this may lead to serious damage or injury. When moving the machine, check that the area around the machine is safe, then sound the horn before starting.
Page 138 Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does not sound, please contact your Komatsu distributor for repairs. 7. Release brake pedal (4), then depress accelerator pedal (8) to move the machine.
Page 139 Position (b): REVERSE Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does not sound, please contact your Komatsu distributor for repairs. USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE WARNING...
Page 140 OPERATION OPERATION OPERATION OPERATION 2. Place the directional selector switch (2) at the N position. 3. Place the directional selector switch actuation switch (3) at the ON position (a). 4. Place the directional selector switch (2) at the F (forward) or R (reverse) position.
Page 141 OPERATION OPERATION STOPPING THE MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Even if the parking brake lever is pulled and set to the LOCK position, there is a danger of the machine moving until the parking brake pilot lamp lights up, so keep the brake pedal depressed.
Page 142: Turning
Check that there is a play of 50 to 100 mm (2.0 to 3.9 in) in the steering wheel. Check also that the steering works properly. If any abnormality is found, please contact your Komatsu distributor for inspection. 3 - 90...
Page 143 OPERATION OPERATION EMERGENCY STEERING (If equipped) CAUTION Never actuate the emergency steering except during emergencies or when checking the function. When using the emergency steering, travel at a speed of less than 5 km/h (3.1 MPH). Emergency steering pilot lamp (green) (2) lights up to inform the operator that the emergency steering system is normal.
Page 144: Operation Of Work Equipment
OPERATION OPERATION OPERATION OF WORK EQUIPMENT WARNING Never raise the boom with the bucket fully loaded when the machine is articulated. There is danger that the machine may tip over. Work equipment control lever (1) can be used to operate the lift arm and bucket as follows.
Page 145 OPERATION OPERATION BUCKET OPERATION Position (e): TILT When the work equipment control lever is pulled further beyond the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position.
Page 146: Handling Hydraulic Quick Coupler
OPERATION OPERATION HANDLING HYDRAULIC QUICK COUPLER WARNING Before operating the machine, check that the attachment is correctly connected. If it is not correctly installed, the attachment may fall off and cause serious injury. Check that the quick coupler attachment switch is at the CONNECT position. Check that the coupler plunger is completely inserted into the attachment.
Page 147 OPERATION OPERATION OPERATION OPERATION 4. Lower the attachment completely to the ground and set it in a stable position. 5. Tilt the coupler forward slowly and lower it slowly so that it separates from the attachment hook. 6. Drive the machine slowly in reverse and separate the attachment from the machine.
Page 148 OPERATION OPERATION INSTALLING THE ATTACHMENT 1. Pull lock (A) of the quick coupler attachment switch in the direction of the arrow (c), and push in to RELEASE position (a). 2. Check that the coupler plunger is completely pulled in. 3. Tilt the coupler forward, drive the machine slowly forward and set so that the attachment hook is aligned with the puller tube.
Page 149 OPERATION OPERATION OPERATION OPERATION 6. Tilt the coupler fully. 7. Keep the control lever at the TILT position, and push in the quick coupler attachment switch to CONNECT position (b). 8. Check that the coupler plunger is completely inserted. 3 - 97...
Page 150: Work Possible Using Wheel Loader
OPERATION OPERATION WORK POSSIBLE USING WHEEL LOADER In addition to the following, it is possible to further increase the range of applications by using various attachments. DIGGING OPERATIONS WARNING Never dig or scoop with the machine articulated. There is danger that the machine may tip over. Never raise the boom with the bucket fully loaded when the machine is articulated.
Page 151 OPERATION OPERATION OPERATION OPERATION 3. If it is difficult to thrust the bucket into the soil, operate the work equipment control lever to the left and right to move the cutting edge of the bucket up and down. DIGGING AND LOADING ON LEVEL GROUND When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the machine forward.
Page 152 OPERATION OPERATION 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-dump angle to more than 20 degrees. Turn the E.C.S.S. switch (if equipped) OFF when carrying out leveling operations.
Page 153 OPERATION OPERATION LOADING OPERATIONS Select the method of operation which will give the minimum amount of turning and travel in order to provide the most efficient method for the jobsite. WARNING Always keep the jobsite flat, and do not operate the steering wheel suddenly or apply the brakes suddenly when the lift arm is raised with a loaded bucket.
Page 154 OPERATION OPERATION V-SHAPE LOADING Position the dump truck so that the direction of approach of the wheel loader is approx. 60 degrees from the direction of approach to the stockpile. After loading the bucket, drive the wheel loader in reverse, then turn it to face the dump truck and travel forward to load the dump truck.
Page 155: 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.
Page 156 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. The following is a guide to suitable tire pressures and speeds when traveling on a paved surface with standard tires.
Page 157: Adjusting Work Equipment Posture
OPERATION OPERATION ADJUSTING WORK EQUIPMENT POSTURE WARNING Stop the machine on flat ground and put blocks in front and behind the wheels. Set parking brake lever to the LOCK position. Secure the front and rear frames with the frame lock bar. Always attach the warning tag to the work equipment control lever.
Page 158 OPERATION OPERATION ADJUSTING BUCKET POSITIONER 1. Lower the bucket to the ground, set to the desired digging angle, return the work equipment control lever to HOLD, then set the work equipment lock lever to the LOCK position and stop the engine. 2.
Page 159 OPERATION OPERATION ADJUSTING FORK POSITIONER 1. Lower the forks to the ground, set to the horizontal position, return the work equipment control lever to the HOLD position, then set the work equipment lock lever to the LOCK position and stop the engine. 2.
Page 160 OPERATION OPERATION BUCKET LEVEL INDICATOR (A) and (B) at the top rear of the bucket are the level indicators. They check the bucket angle during operations. (A): Parallel with cutting edge (B): 90 degrees to cutting edge 3 - 108...
Page 161: Parking Machine
OPERATION OPERATION 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 162 OPERATION OPERATION OPERATION OPERATION 3. Pull parking brake lever (4) and set it to the LOCK position. 4. Operate work equipment control lever (5) to lower the bucket to the ground. 5. Check that the work equipment control lever (5) is at the HOLD position, then set work equipment lock lever (6) to the LOCK position.
Page 163: Checks After Completion Of Operation
OPERATION OPERATION CHECKS AFTER COMPLETION OF OPERATION BEFORE STOPPING ENGINE Check the engine water temperature, engine oil pressure, HST oil temperature, and fuel level with the meters and lamps. If the engine has overheated, do not stop it suddenly. Run the engine at a midrange speed to allow the engine to cool down before stopping it.
Page 164: Handling The Tires
When the tire is peeling (there is separation) When the bead is damaged 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. TIRE PRESSURE Measure the tire pressure before starting operations, when the tires are cool.
Page 165 When traveling continuously with load and carry operations, choose the correct 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, so contact your Komatsu distributor or tire dealer when selecting tires. 3 - 113...
Page 166: Transportation
OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION PROCEDURE As a basic rule, always transport the machine on a trailer. When selecting the trailer, see the weights and dimensions given in Section "SPECIFICATIONS (PAGE 5-2)". Note that the specifications for the weights and dimensions for transportation differ according to the type of tires and type of bucket.
Page 167 OPERATION TRANSPORTATION SECURING MACHINE Load the machine onto a trailer as follows: 1. Lower the work equipment slowly. 2. Check that the work equipment control lever is at the HOLD position, then set the work equipment lock lever to the LOCK position.
Page 168 OPERATION TRANSPORTATION 6. Put blocks in front and behind the wheels, and secure the machine with chains or wire rope to prevent the machine from moving during transportation. In particular, attach the machine securely to prevent it from slipping sideways. Fastening positions 7.
Page 169 OPERATION TRANSPORTATION UNLOADING 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the brakes on the trailer securely and insert locks (1) under the tires to hold the trailer in position. Set the distance (3) between ramps (2) to match the distance between the left and right tires, and make angle (4) of the ramps a maximum of 15°.
Page 170: Lifting Machine
The lifting procedure applies to machines with standard specifications. The method of lifting differs according to attachments and options actually installed on the machine. For the proper lifting procedures, contact your Komatsu distributor. For details of the weight, see "SPECIFICATIONS (PAGE 5-2)".
Page 171 OPERATION TRANSPORTATION Lifting work can be carried out only for machines with lifting marks. Before starting the lifting operation, stop the machine in a horizontal place and do as follows. 1. Start the engine, make sure that the machine is horizontal, then set the work equipment to the travel posture.
Page 172: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 173: Precautions After Completion Of Work
OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 174: Warming-Up Operation For Steering Hydraulic Circuit In Cold Weather
OPERATION COLD WEATHER OPERATION WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER WARNING If the steering wheel is operated and stopped while the oil temperature is low, there may be a time lag before the machine stops turning. In this case, use the frame lock bar to ensure safety, and perform the warm-up operation in a wide place.
Page 175: Long-Term Storage
AFTER STORAGE NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it.
Page 176: Troubleshooting
For details of the permissible towing load for this machine, see Section "SPECIFICATIONS (PAGE 5-2)". 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 177 EMERGENCY TRAVEL OPERATION The normal gear shifting operation is carried out by electric signals. If there should be a failure in the electrical system and the machine does not move, please contact your Komatsu distributor to have the machine moved. NOTICE Always request your Komatsu distributor to carry out the emergency travel operation.
Page 178: If Battery Is Discharged
OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
Page 179 OPERATION TROUBLESHOOTING PRECAUTIONS FOR CHARGING BATTERY When charging the battery, if the battery is not handled correctly, there is danger that the battery may explode. Always follow the instructions in "BATTERY (PAGE 3-121)" and the instruction manual accompanying the charger, and do as follows. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line.
Page 180 OPERATION TROUBLESHOOTING CONNECTING THE BOOSTER CABLE Keep the starting switch of the normal machine and problem machine in the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1. Connect one clip of booster cable (A) to the positive (+) terminal of the problem machine.
Page 181: Other Trouble
TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even...
Page 182 OPERATION TROUBLESHOOTING CHASSIS ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine is running but machine...
Page 183 OPERATION OPERATION TROUBLESHOOTING TROUBLESHOOTING Problem Main causes Remedy Hydraulic system Bucket lacks lifting power Add oil to specified level. See Lack of oil in hydraulic tank EVERY 100 HOURS SERVICE Bucket takes time to go up Replace cartridge, see EVERY Clogged hydraulic filter Excessive bubbles in oil Poor quality oil...
Page 184 OPERATION TROUBLESHOOTING ENGINE ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure caution lamp...
Page 185 OPERATION TROUBLESHOOTING Problem Main causes Remedy Abnormal noise generated Low grade fuel being used Change to specified fuel (combustion or mechanical) Overheating Refer to "Engine coolant temperature gauge is in red range" as above Damage inside muffler Replace muffler) 3 - 133...
Page 186 4 - 1...
Page 187: Maintenance
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 188 MAINTENANCE GUIDES TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged. Clean the radiator core frequently to avoid clogging. Clean and replace the fuel filter frequently. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
Page 189: Outlines Of Service
Komatsu distributor. When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil. FUEL To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the day's work.
Page 190 Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 191 Make sure that the oil is well mixed before sampling. Perform sampling at regular fixed intervals. Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. 4 - 6...
Page 192: Outline Of Electric System
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 193: Wear Parts
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 194: Recommended Fuel, Coolant, And Lubricant
RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
Page 195: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Reservoir Axle Engine oil Transfer Hydraulic Cooling (front and rear) Fuel tank case system system (each) Capacity Liters Specified US gal 5.28 1.85 35.67 4.76 5.02 48.61...
Page 196: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifications, refer to the Komatsu web page or consult your Komatsu distributor. 4 - 11...
Page 197: Standard Tightening Torques 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, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 198: Periodic Replacement Of Safety Critical Parts
Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose clamps 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 critical parts. Replacement Safety critical parts for periodic replacement...
Page 199: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) REPLACE HST OIL FILTER ELEMENT 4- 50 REPLACE HYDRAULIC TANK FILTER ELEMENT 4- 52 WHEN REQUIRED CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT 4- 17 CLEAN INSIDE OF COOLING SYSTEM 4- 20...
Page 200 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 1000 HOURS SERVICE CHANGE OIL IN TRANSFER CASE 4- 48 CLEAN TRANSFER CASE BREATHER 4- 49 REPLACE HST OIL FILTER ELEMENT 4- 50 LUBRICATING 4- 51 CHECK TIGHTENING PARTS OF TURBOCHARGER 4- 51 CHECK PLAY OF TURBOCHARGER ROTOR 4- 51 CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT 4- 51...
Page 201: Service Procedure
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE INITIAL 250 HOURS SERVICE Perform the following maintenance only after the first 250 hours. Replace HST oil filter element Replace hydraulic tank filter element For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS and 2000 HOURS SERVICE.
Page 202: When Required
MAINTENANCE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 203 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 4. Clean the interior of the air cleaner body, cover (3) and evacuator valve (6). NOTICE The inner element must not be used again even after cleaning. When replacing the outer element, replace the inner element at the same time. 5.
Page 204 MAINTENANCE SERVICE PROCEDURE REPLACING ELEMENT 1. Open the engine side cover on the right side of the machine. 2. Remove three clips (2), then remove cover (3). 3. Remove outer element (4). Do not remove inner element (5) at this time, however. 4.
Page 205: Clean Inside Of Cooling System
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 206 MAINTENANCE SERVICE PROCEDURE Liters 13.30 12.16 11.21 10.26 9.50 Amount of water US gal 3.51 3.21 2.96 2.71 2.51 Ratio WARNING Antifreeze is flammable, so keep it away from flame. Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on you. If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.
Page 207 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 11. Drain the coolant from sub-tank (3), clean the inside of the sub-tank, then add water until the coolant level is between the FULL and LOW marks. 12. Stop the engine, wait for approx. 3 minutes, then add coolant until the coolant level is near the coolant filler port, and tighten the cap.
Page 208: Check Oil Level In Transfer Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. Carry out this procedure if there is any sign of oil on the transfer case.
Page 209: Check Axle Oil Level, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK AXLE OIL LEVEL, ADD OIL WARNING When checking the oil level, apply the parking brake and secure the front and rear frames with the frame lock bar. After stopping the engine, the parts and oil are at a high temperature. Wait for the temperature to go down before starting the operation.
Page 210: Clean Axle Case Breather
MAINTENANCE SERVICE PROCEDURE CLEAN AXLE CASE BREATHER WARNING When cleaning the axle breather, apply the parking brake and secure the front and rear frames with the frame lock bar. A: Front B: Rear Remove all mud and dirt from around the breather with a brush. After removing the mud or dirt from around the breather, remove the breather, immerse it in cleaning fluid and clean it.
Page 211: Clean Air Conditioner Condenser
MAINTENANCE SERVICE PROCEDURE CLEAN AIR CONDITIONER CONDENSER WARNING Do not wash the condenser with a steam cleaner. There is danger that the condenser could overheat. If high-pressure water hits your body directly or dirt is sent flying, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment.
Page 212: Clean Radiator Fins And Cooler Fins
CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater checked for dirt or disconnections. 4 - 27...
Page 213: Turn, Replace Bolt-On Cutting Edge
MAINTENANCE SERVICE PROCEDURE TURN, REPLACE BOLT-ON CUTTING EDGE WARNING It is dangerous if the work equipment moves by mistake during the turning or replacement operation. Set the work equipment in a stable condition, stop the engine, then set the work equipment lock lever securely to the LOCK position.
Page 214: Replace Bucket Teeth
MAINTENANCE SERVICE PROCEDURE REPLACE BUCKET TEETH (If equipped) BUCKET WITH TIP TOOTH WARNING If the pin is hit out with strong force, there is danger that the pin may fly out. Check that there is no one in the surrounding area. There is danger of pieces flying during the replacement operation, so always wear protective clothing, such as safety glasses and gloves.
Page 215: Check Air Conditioner
Colorless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributors to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 216: Replace Slow Blow Fuse
MAINTENANCE SERVICE PROCEDURE 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. 1.
Page 217: Checking Function Of Accumulator
If there is no change in the up-and-down movement of the machine, the gas pressure in the accumulator has probably dropped. Please contact your Komatsu distributor to have the accumulator inspected. REMARK Carry out the inspection when the machine is traveling at a speed of at least 10 km/h (6.2 MPH). Even if the travel damper switch is ON, the travel damper is not actuated if the travel speed is less than 10 km/h (6.2 MPH).
Page 218: Selection And Inspection Of Tires
Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the following table. Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when using optional tires.
Page 219 MAINTENANCE SERVICE PROCEDURE CHECK INFLATION PRESSURE OF TIRES WARNING When inflating a tire, check that no one will enter the working area. Use an air chuck which has a clip and which can be fixed to the air valve. While inflating the tire, check the inflation pressure occasionally so that it will not rise too high.
Page 220: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For the following items, see "CHECK BEFORE STARTING (PAGE 3-68)". Check oil level in engine oil pan, add oil Check water separator Check dust indicator Check coolant level, add coolant Check inflation pressure of tires Check electric wiring Check monitor panel Check fuel level, add fuel...
Page 221: Every 50 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE DRAIN WATER, SEDIMENT FROM FUEL TANK Loosen valve (1) on the left side of the tank so that the sediment and water will be drained together with fuel. 4 - 36...
Page 222: Every 100 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 100 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATE REAR AXLE PIVOT PIN (2 places) 1. Using a grease pump, pump in grease through the grease fittings marked by the arrows. 2.
Page 223: Check Oil Level In Hydraulic Tank, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 224: Every 250 Hours Service
If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4 - 39...
Page 225 If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 226: Check Parking Brake
2. Pull the parking brake lever fully to the LOCK position, and check if the parking brake can hold the machine in position. 3. If any problem is found, please contact your Komatsu distributor. CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST CHECKING 1.
Page 227: Check For Loose Wheel Hub Bolts, Tighten
Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove. In case any of the following occurs, ask the Komatsu distributor in your territory to replace the belts with new ones. • The fan belt has elongated, leaving little allowance for adjustment.
Page 228: Clean Element In Air Conditioner Recirculation Filter
If the brake oil pressure caution lamp lights up when the brake has been depressed 5 or less times, the gas pressure in the accumulator has probably dropped. Please contact your Komatsu distributor to have the accumulator inspected.
Page 229: Lubricating
MAINTENANCE SERVICE PROCEDURE LUBRICATING NOTICE On jobsites where there is a lot of heavy-duty work, or on jobsites where operations are carried out continuously for more than eight hours, reduce the greasing interval and carry out greasing more frequently. 1. Put the work equipment horizontally in contact with the ground, then stop the engine.
Page 230: Every 500 Hours Service
4. Loosen drain plug (P) and drain the oil. Be careful not to get oil on yourself. 5. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 6. Tighten drain plug (P).
Page 231: Replace Fuel Filter Cartridge
MAINTENANCE SERVICE PROCEDURE REPLACE FUEL FILTER CARTRIDGE WARNING The engine is at high temperature immediately after the machine has been operated. Wait for the engine to cool down before replacing the filter. Do not bring fire or sparks near the fuel. REMARK If the machine has run out of fuel, use Steps 6 to 9 to bleed the air.
Page 232: Clean Water Separator Strainer
MAINTENANCE SERVICE PROCEDURE CLEAN WATER SEPARATOR STRAINER WARNING The engine is at high temperature immediately after the machine has been operated. Wait for the engine to cool down before replacing the filter. Do not bring fire or sparks near the fuel. 1.
Page 233: Every 1000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Maintenance for every 50, 100, 250 and 500 hours service should be carried out at the same time. CHANGE OIL IN TRANSFER CASE WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 234: Clean Transfer Case Breather
MAINTENANCE SERVICE PROCEDURE CLEAN TRANSFER CASE BREATHER 1. Remove cover (1). 2. Remove the mud and dirt from around the breather (2), then remove breather (2). After removing the breather, take steps to prevent dirt or dust from entering the mount. 3.
Page 235: Replace Hst Oil Filter Element
MAINTENANCE SERVICE PROCEDURE REPLACE HST OIL FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
Page 236: Lubricating
Contact your Komatsu distributor to have the rotor play checked. CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT Since inspection and replacement of the fan belt requires special tools, contact your Komatsu distributor. REMARK The machine is equipped with an auto tensioner, so there is no need to adjust the tension.
Page 237: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 238: Replace Hydraulic Tank Breather Element
MAINTENANCE SERVICE PROCEDURE REPLACE HYDRAULIC TANK BREATHER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
Page 239: Change Axle Oil
MAINTENANCE SERVICE PROCEDURE CHANGE AXLE OIL WARNING When changing the oil, apply the parking brake and secure the front and rear frames with the frame lock bar. After the engine is stopped, the parts and oil are at high temperature, and may cause burns. Wait for the temperature to go down before starting the operation.
Page 240: Clean Brake Circuit Strainer
MAINTENANCE SERVICE PROCEDURE CLEAN BRAKE CIRCUIT STRAINER WARNING After the engine is stopped, the parts and oil are at high temperature, and may cause burns. Wait for the temperature to go down before starting the operation. When the rubber hose is removed, oil may spurt out, so turn it slowly to release the internal pressure, then remove it carefully. 1.
Page 241: Check Brake Disc Wear
(3) and plate (4). 3. If the inspection gauge can be inserted into the tooth portion, the disc has reached the wear limit. Please ask your Komatsu distributor to carry out the replacement. 4. After checking, install check plug (1).
Page 242: Checking Function Of Accumulator
Replace the accumulator every 4000 hours or every 2 years. CHECK ALTERNATOR, STARTING MOTOR The brush may be worn or have no grease on the bearing, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
Page 243: Every 4000 Hours Service
CHECK WATER PUMP Check that there is no play in the pulley or any grease leakage, water leakage, or clogging of the drain hole. If any problem is found, contact your Komatsu distributor for disassembly and repair or replacement. 4 - 58...
Page 244 5 - 1...
Page 245: Specifications
12,275(27,066) kg (165 lb))(With bolt on cutting edge) Normal load kg(lb) 3,540(7,806) Bucket capacity Heaped (cu.yd) 2.0(2.6) Engine model Komatsu SAA6D102E diesel engine Flywheel horsepower kW{HP}/rpm 101{135}/2000 A Overall length mm(ft in) 7,310(24') B Overall height mm(ft in) 3,200(10'6") C Max. dimension when shaking bucket mm(ft in) 5,195(17'1")
Page 246 6 - 1...
Page 247: Attachments, Options
17.5-25-16PR (L2: Traction) products 20.5-25-12PR (L2: Traction) Soft ground 17.5-25-16PR (L2: Traction) BOC indicates a bolt-on type cutting edge. The displayed travel speed changes according to the tire size, so when installing optional tires, please contact your Komatsu distributor. 6 - 2...
Page 248: Handling Fork Tool
ATTACHMENTS, OPTIONS HANDLING FORK TOOL HANDLING FORK TOOL EXPLANATION OF COMPONENTS (1) Work equipment control lever WORK EQUIPMENT LEVER Use this lever (1) to operate the lift arm and fork. NOTICE Do not use the FLOAT position when lowering the fork. Position (a): RAISE When the work equipment control lever is pulled further beyond the RAISE position, the lever is...
Page 249: Operation
ATTACHMENTS, OPTIONS HANDLING FORK TOOL OPERATION The operating speed of the forklift is determined according to the configuration of the ground, condition under foot, and size of the operating area. When operating the forklift, maintain the engine speed at near full speed, and carry out the operation with the speed range in 1st or 2nd.
Page 250 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING FORK TOOL HANDLING FORK TOOL 5. Check that there is no obstacle behind the machine, lower the load as far as possible, then drive the machine slowly in reverse. 6. Lower the load until it is close to the ground surface (30 inches from the ground surface).
Page 251 ATTACHMENTS, OPTIONS HANDLING FORK TOOL UNLOADING 1. Set several inches above the position of the stacked load. 2. Drive slowly forward to the stacking point with the forks horizontal. 3. Lower the load. 4. Drive the machine slowly in reverse and remove the forks from the load.
Page 252: Index
INDEX INDEX <A> HANDLING FORK TOOL ADJUSTING WORK EQUIPMENT EXPLANATION OF COMPONENTS POSTURE 3-105 OPERATION AIR CONDITIONER 3- 59 HANDLING HYDRAULIC QUICK AM/FM RADIO-CASSETTE STEREO 3- 51 COUPLER 3- 94 HANDLING OIL, FUEL, COOLANT, AND <C> PERFORMING OIL CLINIC CAB DOOR INNER LOCK 3- 47 HANDLING THE TIRES 3-112...
Page 253 AND LUBRICANT TURNING 3- 90 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR <W> PRODUCTS OTHER THAN WEAR PARTS KOMATSU GENUINE OIL 4- 11 WEAR PARTS LIST USE OF FUEL, COOLANT AND WORK POSSIBLE USING WHEEL UBRICANTS ACCORDING TO LOADER 3- 98 AMBIENT TEMPERATURE 4- 10 <S>...

Komatsu GALEO WA250PTL-5 Installation Operation & Maintenance

Section 1

Section 2

Maintenance Schedule Chart

Quick Links

Chapters

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Komatsu GALEO WA250PTL-5

Summary of Contents for Komatsu GALEO WA250PTL-5

Table of Contents