If the Komatsu WA500-3 loader has no movement in forward and reverse and the ECM shows 28 with no error code, it could indicate an issue with the 1st ECMV fill switch. According to the context, item 28 refers to the 1st ECMV fill switch. A malfunction or disconnection in this switch can prevent the machine from engaging the drive system, even if no error code is displayed.

This answer is automatically generated

Summary of Contents for Komatsu Avance WA500-3

Page 2 1 - 1...
Page 3: Foreword
Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
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 3-63)". 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 On the lower right of maintenance 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 AND POSITION POSITION OF SERVICE METER TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SAFETY SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS...
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 EVERY 250 HOURS SERVICE 4- 41 EVERY 500 HOURS SERVICE 4- 48 EVERY 1000 HOURS SERVICE 4- 54 EVERY 2000 HOURS SERVICE 4- 61 EVERY 4000 HOURS SERVICE 4- 68 EVERY 8000 HOURS SERVICE 4- 70 SPECIFICATIONS SPECIFICATIONS ATTACHMENTS, OPTIONS SELECTING BUCKET AND TIRES HANDLING E.C.S.S.(ELECTRONIC CONTROLLED SUSPENSION SYSTEM)
Page 14 2 - 1...
Page 15: Safety
SAFETY SAFETY SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS GENERAL PRECAUTIONS SAFETY RULES 2- 13 IF ABNORMALITIES ARE FOUND 2- 13 CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 13 FIRE EXTINGUISHER AND FIRST AID KIT 2- 13 SAFETY FEATURES 2- 13 KEEP MACHINE CLEAN 2- 14 INSIDE OPERATOR'S COMPARTMENT...
Page 16 SAFETY SAFETY PRECAUTIONS FOR OPERATION 2- 22 STARTING ENGINE 2- 22 CHECKS BEFORE STARTING ENGINE 2- 22 PRECAUTIONS WHEN STARTING 2- 22 PRECAUTIONS IN COLD AREAS 2- 23 OPERATION 2- 24 CHECKS BEFORE OPERATION 2- 24 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 24 PRECAUTIONS WHEN TRAVELING 2- 25...
Page 17 SAFETY SAFETY PRECAUTIONS WITH TIRES 2- 41 HANDLING TIRES 2- 41 PRECAUTIONS WHEN STORING TIRES 2- 41 2 - 4...
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: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS (1) Caution before starting (2) Caution for safety lock lever (3) Caution when traveling in reverse 2 - 6...
Page 20 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Caution for parking brake (5) Do not enter (6) Caution for safety bar 2 - 7...
Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (7) Caution for going close to electric cables (09801-13001) (8) Caution when coolant is at high temperature (9) Caution when oil is at high temperature 2 - 8...
Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (10) Caution when handling battery cable Please request part number 425-93-21511 for safety labels ((1) to (4)). Please request part number 421-93-21310 for safety labels ((5), (6), (8) to (10)). (11) Caution when handling battery (12) Caution to prevent explosion (09659-53000) (13) Do not climb on hood (09805-13000) 2 - 9...
Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (14) "Do not go under work equipment" sign (09807-C1683) (15) "Do not open when engine is running" sign (09667-03001) (16) "Do not come near machine" sign (09812-03000) 2 - 10...
Page 24 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (17)"Do not modify ROPS" sign (09620-30201) (18) Caution for high voltage (6217-81-9270)(6217-81-9280) (19) Jump start prohibited (09842-A0481) 2 - 11...
Page 25 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (20) Caution when handling battery (09664-30000) (For USA, Puerto Rico) Safety label (11) is stick on the machine by the battery maker. Safety label (18) is stuck to the engine controller and engine cylinder head cover. Safety label (19) is stick on the starting motor.
Page 26: 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 in this manual when operating or performing maintenance on the machine. If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger.
Page 27: 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 28: 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 29: Do Not Get Caught In Articulated Portion
SAFETY GENERAL PRECAUTIONS DO NOT GET CAUGHT IN ARTICULATED PORTION If the clearance at the articulating portion changes, it will lead to serious personal injury. Do not allow anyone to come inside the articulation range. The clearance in the area around the work equipment changes according to the movement of the link.
Page 30: 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 31: 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 32: 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 33: 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 34: 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 - 21...
Page 35: 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 (1). 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 36: 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 37: 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 38: 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 - 25...
Page 39: 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. Keep the work equipment at height (A) 40 to 50 cm (16 to 20 in) from the ground, and in case of emergency, quickly lower the bucket to the ground to help the machine to stop.
Page 40: 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 41: 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 42: Parking Machine
SAFETY PRECAUTIONS FOR OPERATION PARKING MACHINE Park the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding. Lower the work equipment completely to the ground. When leaving the machine, set safety lock lever (1) to the LOCK position and parking brake switch (2) to the ON position, and stop the engine.
Page 43: 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 44: 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 45: 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 46: Towing
SAFETY PRECAUTIONS FOR OPERATION TOWING WHEN TOWING When towing or being towed, mistakes in the method of selecting and inspecting the wire rope or drawbar, or in the method of towing may lead to serious personal injury. For details of the procedure for towing, see the "METHOD OF TOWING MACHINE (PAGE 3-92)" Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the machine being towed.
Page 47: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG Always attach the "DO NOT OPERATE" warning tag to work equipment control lever (1) in the operator's cab to alert others that you are performing service of maintenance on the machine. Attach additional warning tags around the machine if necessary.
Page 48: 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 landslides, falling rocks, or flooding. Lower the work equipment completely to the ground and stop the engine.
Page 49: Two Workers For Maintenance When Engine Is Running
SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE Lock the frame with safety bar (4) to prevent the machine from articulating. TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal 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 50: 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 Do not allow any unauthorized personnel into the area when servicing the machine.
Page 51: Attachments
SAFETY PRECAUTIONS FOR MAINTENANCE ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area. NOISE If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
Page 52: 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 53: Waste Materials
SAFETY PRECAUTIONS FOR MAINTENANCE WASTE MATERIALS To prevent pollution, pay careful attention to the method of disposing of waste materials. Always put oil drained from your machine in containers. Never drain oil directly onto the ground or dump into the sewage system, rivers, the sea, or lakes.
Page 54: 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 3-79)"...
Page 56 3 - 1...
Page 57: Operation
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Bucket Turn signal lamp Lift arm Head lamp Tilt lever (10) Lift cylinder Bucket cylinder (11) Front wheel Front working lamp (12) Rear working lamp ROPS (13) Rear combination lamp Rear wheel 3 - 2...
Page 58: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Front wiper switch (13) Starting switch Rear wiper switch (14) Car radio (if equipped) Gearshift lever stopper (15) Kickdown switch Air conditioner panel (if equipped) (16) Hold switch Gearshift lever (17) Lift arm control lever Directional lever (18)
Page 59 OPERATION GENERAL VIEW MAIN MONITOR MAINTENACNE MONITOR E.C.S.S. switch (switch, pilot lamp)(if equipped) (16) Fuel level Auto-greasing switch (if equipped) (17) Engine water temperature gauge Emergency steering pilot lamp (if equipped) (18) Torque converter oil temperature gauge Turn signal pilot lamp (19) Remote positioner LOWER position set switch Head lamp high beam pilot lamp...
Page 60: 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 MONITOR SYSTEM Meter display portion...
Page 61 When this happens, 88 is displayed on the speedometer, and 8 is displayed on the transmission shift indicator. 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.
Page 62 OPERATION EXPLANATION OF COMPONENTS WARNING DISPLAY Central check lamp (CHECK) Engine oil pressure caution pilot lamp Central caution lamp (CAUTION) Battery charge caution pilot lamp Engine water level caution pilot lamp Air cleaner clogging caution pilot lamp Engine oil level caution pilot lamp Emergency steering pilot lamp (red)(If equipped) Brake oil pressure caution pilot lamp 3 - 7...
Page 63 OPERATION EXPLANATION OF COMPONENTS 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 central check lamp (CHECK) (1) will also flash.
Page 64 OPERATION EXPLANATION OF COMPONENTS ENGINE WATER LEVEL CAUTION PILOT LAMP This lamp (3) warns that the coolant level in the radiator has dropped. When carrying out the checks before starting (starting switch ON, engine stopped): If the level of the coolant in the radiator is low, the caution pilot lamp and central CHECK lamp will flash.
Page 65 OPERATION EXPLANATION OF COMPONENTS BRAKE OIL PRESSURE CAUTION PILOT LAMP This lamp (5) warns the operator that the brake oil pressure has dropped. When carrying out checks before starting: When the engine is stopped, the brake oil pressure circuit is not actuated, so the caution pilot lamp and central CHECK lamp are also off.
Page 66 OPERATION EXPLANATION OF COMPONENTS AIR CLEANER CLOGGING CAUTION PILOT LAMP When the engine is running, this lamp (8) warns the operator that the air cleaner element is clogged. Check before starting: OFF When operating: If the air cleaner becomes clogged, the caution pilot lamp and central CHECK lamp will flash.
Page 67 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION Parking brake pilot lamp Fuel gauge Engine pre-heating pilot lamp (10) Engine water temperature gauge Front working lamp pilot lamp (11) Torque converter oil temperature gauge Rear working lamp pilot lamp (12) Service meter Transmission cut-off pilot lamp (13) Speedometer...
Page 68 OPERATION EXPLANATION OF COMPONENTS ENGINE PRE-HEATING PILOT LAMP This lamp (2) informs the operator of the pre-heating status of the electrical intake air heater. This lamp lights up when the starting switch is turned to the ON position, and goes out when the pre-heating is completed. The time that it remains lighted up differs according to the water temperature when the engine is started.
Page 69 OPERATION EXPLANATION OF COMPONENTS TURN SIGNAL PILOT LAMP When the turn signal lamp flashes, this lamp (6) also flashes. HIGH BEAM PILOT LAMP This lamp (7) lights up when the head lamp is at high beam. TRANSMISSION AUTO SHIFT/MANUAL SELECTOR PILOT LAMP This lamp (8) lights up when the transmission manual selector switch is operated and the transmission shift is changed to manual mode.
Page 70 OPERATION EXPLANATION OF COMPONENTS METERS FUEL GAUGE This gauge (9) 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 71 OPERATION EXPLANATION OF COMPONENTS SPEEDOMETER This meter (13) indicates the travel speed of the machine. TRANSMISSION SHIFT INDICATOR This indicator (14) shows the present speed range of the transmission. When the directional lever is at the N position, N is displayed on the indicator.
Page 72: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Starting switch Hazard lamp switch Transmission cut-off switch Kickdown switch Front working lamp switch (10) Front wiper switch Rear working lamp switch (11) Rear wiper switch Transmission auto shift/manual selector switch (12) Cigarette lighter (If equipped) Lamp switch (13) Room lamp switch...
Page 73 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch (1) 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, all electric circuits are turned off and the engine stops.
Page 74 OPERATION EXPLANATION OF COMPONENTS FRONT WORKING LAMP SWITCH WARNING Always turn the working lamp off before traveling on public roads. When turning on the front working lamp, turn the lamp switch to the ON position for the side clearance lamp or ON position for the head lamp, then operate the switch (3).
Page 75 OPERATION EXPLANATION OF COMPONENTS LAMP SWITCH This switch (6) is used to light up the front lamps, side clearance lamps, tail lamps, and instrument panel. Position (a): OFF Position (b): Side clearance lamps, tail lamps, and instrument panel light up Position (c): Head lamps light up in addition to lamps at (b) position REMARK The lamp switch can be operated regardless of the position of the...
Page 76 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 (8) is used in emergencies, such as when the machine breaks down and has to be parked on the road.
Page 77 OPERATION EXPLANATION OF COMPONENTS REAR WIPER SWITCH Turn lever (C) on switch (11) to operate the rear wiper. Position (a): Washer liquid is sprayed out Position (b): OFF Position (c): Wiper is operated Position (d): Washer liquid is sprayed out, wiper is operated CIGARETTE LIGHTER (If equipped) This is used to light cigarettes.
Page 78 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 switch (14) is used for actuating the parking brake.
Page 79 OPERATION EXPLANATION OF COMPONENTS POWER WINDOW SWITCH WARNING When closing the window glass, be careful not to get anyone's hands or head caught. There is danger of serious injury if anyone is caught in the window glass. CAUTION After fully opening or fully closing the window glass, do not keep the switch operated in the same direction. This may cause failure of the power window.
Page 80: Control Levers, Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS, PEDALS Gearshift lever Bucket control lever Directional lever Lift arm control lever Gearshift lever stopper Brake pedal Safety lock lever (for work equipment lever) Accelerator pedal GEARSHIFT LEVER This lever (1) changes the speed range of the transmission. MANUAL SHIFT This machine has a 4-FORWARD, 4-REVERSE speed transmission.
Page 81 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS REMARK The length of the lever can be adjusted to 3 stages (positions (A), (B), (C)). To adjust the length, remove the screw at the bottom of the lever knob, slide the knob to the desired position, then tighten the screw again.
Page 82 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS REMARK The 1st position for the gearshift lever fixes the transmission in 1st. There is no automatic shifting of the transmission. When shifting down from 2nd to 1st, press the kick-down switch on the lift arm control lever.
Page 83 OPERATION EXPLANATION OF COMPONENTS GEARSHIFT LEVER STOPPER This stopper (3) prevents the gearshift lever from entering the 3rd or 4th positions when working. Position (a): Stopper actuated. Position (b): Stopper released. SAFETY LOCK LEVER (FOR WORK EQUIPMENT LEVER) WARNING When leaving the operator's compartment, set the safety lock lever securely to the LOCK position.
Page 84 OPERATION EXPLANATION OF COMPONENTS LIFT ARM CONTROL LEVER This lever (6) is used to operate the lift arm. Position (a): RAISE When the lift arm control lever is pulled further from the RAISE position, the lever is stopped in this position until the lift arm reaches the preset position of the kickout, and the lever is returned to the HOLD position.
Page 85: Steering Column Tilt Lever
OPERATION EXPLANATION OF COMPONENTS ACCELERATOR PEDAL This pedal (8) controls the engine speed and output. The engine speed can be freely controlled between low idle and full speed. STEERING COLUMN TILT 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.
Page 86: Cap With Lock
OPERATION EXPLANATION OF COMPONENTS CAP WITH LOCK The radiator sub tank filler port, fuel tank filler port, transmission filler port (if equipped), and hydraulic tank filler port (if equipped) are equipped with locks. Use the starting switch key to open or close the cap. METHOD OF OPENING AND CLOSING CAP WITH LOCK TO OPEN THE CAP 1.
Page 87: Safety Bar
OPERATION EXPLANATION OF COMPONENTS SAFETY BAR WARNING When carrying out maintenance or transporting the machine, always fit the safety bar. Always remove the safety bar for general travel operations. If it is not removed, the steering wheel cannot be used for steering. This is extremely dangerous.
Page 88: Backup Alarm
OPERATION EXPLANATION OF COMPONENTS BACKUP ALARM This sounds an alarm when the directional lever is set to the R position. It is used to warn people behind the machine that the machine will travel in reverse. DUST INDICATOR This device indicates clogging of the air cleaner. Depending on the degree of clogging of the element, red line (1) appears in the transparent portion.
Page 89: Slow Blow Fuse
OPERATION EXPLANATION OF COMPONENTS FUSE BOX 2 Fuse capacity Name of circuit Front working lamp Rear working lamp Air conditioner 1 Air conditioner 2 Wiper, washer Auto shift Cigarette lighter (if equipped), radio (if equipped) Rotating lamp (if equipped) Air suspension (if equipped) (10) Auto-greasing (if equipped) (11)
Page 90: Operation
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Before starting the engine, walk around the machine and look at the underside of chassis for anything unusual like loose bolts and nuts, leakage of fuel, oil and coolant.
Page 91 Check for any loose or damaged bolts. If any loose bolts are found tighten them to 927 ± 103 Nm (94.5 ± 10.5 kgm , 683.5 ± 75.9 lbft). If any bolts are damaged, replace them with genuine Komatsu bolts. 13. Clean cab window.
Page 92 OPERATION OPERATION 14. 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 93 2. Check that all the monitors, gauges, and the central warning lamp light up for approx. 3 seconds and the alarm buzzer sounds for approx. 1 sec. If the lamps do not light up, there is probably a failure or disconnection. Contact your Komatsu distributor inspection. 3 - 38...
Page 94 OPERATION OPERATION CHECK COOLANT LEVEL, ADD COOLANT WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to check the coolant level in this condition, there is a hazard of burns.
Page 95 OPERATION OPERATION 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. 1.
Page 96 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When filling with fuel, do not add any more fuel after the fuel supply has automatically stopped. If too much fuel is added, there is danger that the fuel may expand because of the rise in the ambient temperature and cause the fuel to overflow. Spilled fuel may cause fire, so always wipe off any spilled fuel completely.
Page 97 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. CHECK INFLATION PRESSURE OF TIRES Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work.
Page 98 If the wall or rubber sheet are damaged or have come off, please contact your Komatsu distributor for repairs.
Page 99 OPERATION OPERATION ADJUSTMENT SEAT ADJUSTMENT WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. Adjust the seat position at the beginning of each shift or when operators change. Adjust the seat so that the brake pedal can be depressed all the way down with the operator's back against the backrest. (A) Fore-and-aft adjustment Pull lever (1) up, set the seat to the desired position, then release the lever.
Page 100 OPERATION OPERATION (G) Adjusting headrest angle Rotate the headrest to the front or rear. (H) Adujusting armrest angle Adjust angle of armrest by rotating knob (5) (left side only). Adjustment range: 30 degrees (forward tilt: 25 degrees, backward tilt:5 degrees) Also, when armrest is turned, it will spring up.
Page 101 OPERATION OPERATION WRIST REST HEIGHT ADJUSTMENT LEVER The height of lift rest (1) can be adjusted easily with adjustment lever (2). Turn adjustment lever (2) in the loosening direction and adjust the height of lift rest (1) properly, then turn adjustment lever (2) to the fixing direction.
Page 102 OPERATION OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING Before starting the engine, check that the safety lock lever is securely at the LOCK position. If the work equipment control lever is touched by accident when starting the engine, the work equipment may move unexpectedly and cause serious damage or personal injury.
Page 103 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. 3 - 48...
Page 104: Starting Engine
OPERATION OPERATION STARTING ENGINE WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a 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 105 OPERATION OPERATION OPERATION OPERATION 3. After the engine starts, release the key in starting switch (1). The key will automatically return to the ON position. 4. Immediately after starting the engine, run it at idling. Do not depress the accelerator pedal or operate the work equipment during this time.
Page 106 OPERATION OPERATION AUTOMATIC WARMING-UP OPERATION After the engine starts, if the engine water temperature is low, the warming-up operation is automatically carried out. When the water temperature goes above 50°C (122°F), the warming-up operation is canceled. REMARK The automatic warming-up operation changes as shown in the diagram on the right according to the engine water temperature.
Page 107: 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 108 Run the engine under a light load until engine water temperature gauge (2) and torque converter oil temperature gauge (3) are in the green range. 4. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 53...
Page 109: 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 apart from 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 110: Moving The Machine (Directional, Speed), Stopping The Machine
OPERATION OPERATION MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE 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 to get near the machine. Clear the machine's travel path of any obstacle.
Page 111 OPERATION OPERATION OPERATION OPERATION 4. Depress right brake pedal (8) and turn parking brake switch (9) to the OFF (RELEASE) position to release the parking brake. Keep right brake pedal (8) depressed. REMARK If the parking brake is still actuated when parking brake switch (9) is at the OFF (RELEASE) position, turn the parking brake switch ON, then turn it OFF again.
Page 112 OPERATION OPERATION CHANGING GEAR SPEED WARNING When traveling at high speed, do not shift gear suddenly. Use the brake to reduce the travel speed before shifting gear. Shift gear as follows. Move the gearshift lever (1) to the desired position to shift gear. When carrying out digging or loading operations, the operation is carried out in 1st or 2nd, so use the gearshift lever stopper.
Page 113 OPERATION OPERATION 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. Do not switch between FORWARD and REVERSE when traveling at high speed.
Page 114 OPERATION OPERATION STOPPING THE MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. 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. NOTICE Never use the parking brake switch to brake the machine when traveling except in an emergency.
Page 115: 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 - 60...
Page 116: Operation Of Work Equipment
OPERATION OPERATION 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 CONTROL LEVER Position (a): RAISE Position (b): HOLD The lift arm is stopped and held in position. Position (c): LOWER Position (d): FLOAT The lift arm moves freely under external force.
Page 117 OPERATION OPERATION BUCKET CONTROL LEVER Position (a): TILT Position (b): HOLD The bucket is kept in the same position. Position (c): DUMP When the bucket control lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position.
Page 118: 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 Always set the machine facing directly to the front when carrying out digging or scooping operations. Never carry out these operations with the machine articulated.
Page 119 OPERATION OPERATION OPERATION 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.
Page 120 OPERATION OPERATION DIGGING AND LOADING ON LEVEL GROUND When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the machine forward. Always be careful not to load the bucket on one side and cause an unbalanced load. This operation should be carried out in 1st gear.
Page 121 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 dumping angle to more than 20 degrees. 1.
Page 122 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 working area flat. Do not turn suddenly or apply the brake suddenly when traveling with a raised load. These actions are dangerous.
Page 123 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 124: 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 125 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 126: 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. Apply the parking brake. Secure the front and rear frames with the safety bar. Always attach the warning tag to the work equipment control lever. Do not go under the work equipment when the arm is raised.
Page 127 OPERATION OPERATION ADJUSTING BUCKET POSITIONER 1. Lower the bucket to the ground, set to the desired digging angle, return the bucket control lever to the HOLD position, then lock the work equipment control lever with the safety lock lever and stop the engine. 2.
Page 128: Removal And Installation Of The Bucket
OPERATION OPERATION REMOVAL AND INSTALLATION OF THE BUCKET WARNING When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment. When the bucket is removed, place it in a stable condition.
Page 129 OPERATION OPERATION OPERATION OPERATION 4. Pull out and remove bucket hinge pin (4) on both sides of the bucket. 5. Disconnect the lift arm and bucket. INSTALLING THE BUCKET 1. Set cord ring (2) on top of lift arm boss (1) as shown in the diagram.
Page 130 Assemble a pin that has no grease hole at the bucket link. 9. Coat the bucket hinge pin and bucket link pin with grease. For details, see "LUBRICATING (PAGE 4-45)". For details of removing and installing the bucket, please contact your Komatsu distributor. 3 - 75...
Page 131: 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 132 OPERATION OPERATION OPERATION OPERATION 3. Turn parking brake switch (4) to ON to apply the parking brake. NOTICE When the parking brake is applied, the transmission is automatically returned to neutral. 4. Operate lift arm control lever (5) to lower the bucket to the ground.
Page 133: Checks After Completion Of Operation
OPERATION OPERATION CHECKS AFTER COMPLETION OF OPERATION Check the engine water temperature, engine oil pressure, torque converter oil temperature, and fuel level with the machine monitor. 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 134: 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 135 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 - 80...
Page 136: Transportation
OPERATION TRANSPORTATION TRANSPORTATION Always obey the traffic regulations when transporting the machine by road. 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 137: Method Of Securing Machine
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 blocks under the tires to ensure that the trailer does not move. Then fix the ramps in line with the centers of the trailer and the machine.
Page 138 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 5. Lock the front and rear frame with the safety bar. 6. Put blocks in front of and behind the wheels and secure the machine with chains or wire rope of a suitable strength to prevent the machine from moving during transportation. NOTICE Always retract the antenna and reassemble the mirrors so that they are within the width of the machine.
Page 139: Method Of Lifting Machine
The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor. For the weight of the standard specification machine, see "WEIGHT TABLE (PAGE 3-85)".
Page 140 OPERATION TRANSPORTATION LOCATION OF LIFTING POSITION MARK WEIGHT TABLE Operating Front wheel Rear wheel Center of gravity weight load load (from front axle) 28,220kg 13,090kg 15,130kg 1,920mm WA500-3 (62215 lb) (28860 lb) (33355 lb) (6 ft 4 in) 3 - 85...
Page 141 OPERATION TRANSPORTATION LIFTING PROCEDURE The machine can be lifted only if it has hook mark labels. When lifting the machine, stop the machine on level ground 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 142: 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 143: 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 144: After Cold Weather
OPERATION COLD WEATHER OPERATION AFTER COLD WEATHER When the season changes and the weather becomes warmer, do as follows. Replace all fuel and oil with fuel and oil of the specified viscosity. For details, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-9)". WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER WARNING If the steering wheel is operated and stopped while the oil temperature is...
Page 145: 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 146: Troubleshooting
OPERATION TROUBLESHOOTING TROUBLESHOOTING WHEN MACHINE RUNS OUT OF FUEL When starting after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting. PROCEDURE FOR BLEEDING AIR CAUTION This engine consists of higher precision parts than on the conventional fuel injection pump and nozzle, so if dirt gets in, it will cause problems.
Page 147: Method Of Towing Machine
Towing is only permitted in order to move a disabled machine to a place where it is possible to carry out inspection and maintenance. It must not be towed for long distances. Please consult your Komatsu distributor for information about towing a disabled machine. This machine must not be towed except in emergencies. When towing the machine, take the following precautions.
Page 148 OPERATION TROUBLESHOOTING Towing may be carried out under various differing conditions, so it is impossible to determine beforehand the requirements for towing. Towing on flat horizontal roads will require the minimum rimpull, while towing on slopes or on uneven road surfaces will require the maximum rimpull.
Page 149 OPERATION TROUBLESHOOTING METHOD OF RELEASING PARKING BRAKE Please ask your Komatsu distributor to release the parking brake. WARNING Stop the machine on a flat surface when releasing the parking brake, and check that the surroundings are safe. In emergencies or when the parking brake must be released on a hill, block the tires carefully before releasing the brake.
Page 150 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 151: 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 152 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 3-88)" 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 153 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 154: 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 155 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 Transmission Parking brake is applied...
Page 156 OPERATION OPERATION TROUBLESHOOTING TROUBLESHOOTING Problem Main causes Remedy Steering Steering wheel is heavy Defective hydraulic system ( Check, repair) Lack of oil Add oil to specified level. See EVERY 100 HOURS SERVICE Steering wheel is loose Play in steering cylinder pin Grease bearing or replace pin and bushing where there is play...
Page 157 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 pilot...
Page 158 OPERATION OPERATION TROUBLESHOOTING TROUBLESHOOTING Problem Main causes Remedy Error code is displayed on monitor Alarm buzzer sounds Please contact your Komatsu distributor Engine suddenly lost power (entered delayed mode) 3 - 103...
Page 159 OPERATION TROUBLESHOOTING RELATIONSHIP OF ELECTRONIC CONTROL SYSTEM 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. MAIN MONITOR FAILURE DISPLAY Option Transmission Electronic governor...
Page 160 OPERATION TROUBLESHOOTING Option Transmission Electronic governor E.C.S.S. Work equipment Joystick Action control system system control system control system control system opera- Condi- Condi- Condi- Condi- Condition Problem Problem Problem Problem Problem tion of tion of tion of tion of system system system system...
Page 161 OPERATION TROUBLESHOOTING Option Transmission Electronic governor E.C.S.S. Work equipment Joystick Action control system system control system control system control system opera- Condi- Proble Condi- Condi- Proble Condi- Condition Problem Problem Problem tion of tion of tion of tion of system system system machine...
Page 162 OPERATION TROUBLESHOOTING Option Transmission Electronic governor E.C.S.S. Work equipment Joystick Action control system system control system control system control system opera- Condi- Proble Condi- Condi- Proble Condi- Condition Problem Problem Problem tion of tion of tion of tion of system system system machine...
Page 163 OPERATION TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM Problem system Error Item Code Short circuit Disconnection Back-up lamp relay None – – F ECMV Sol. R ECMV Sol. 1st ECMV Sol. 2nd ECMV Sol. 3rd ECMV Sol. 4th ECMV Sol. None – – Joystick direction switch signal Direction switch signal Range switch signal...
Page 164 OPERATION TROUBLESHOOTING WORK EQUIPMENT CONTROL SYSTEM Problem system Error Item Code Short circuit Disconnection Damping Sol. Damping Sol. HOT end To power source Damping Sol. return end To power source 46 to 48 None – – Boom kick-out relay Boom RAISE/LOWER switch Boom angle potentiometer JOYSTICK CONTROL SYSTEM Problem system...
Page 165 OPERATION TROUBLESHOOTING ELECTRONIC GOVERNOR CONTROL SYSTEM Error Electronic governor Item Code controller fault code Power source abnormality 1 Abnormality in common rail pressure (control system 2nd stage) No-force feed of pump (2nd stage) Abnormality in controller (drive circuit) Abnormality in Ne sensor Abnormality in G sensor Abnormality in accelerator sensor Abnormality in boost pressure sensor...
Page 166 4 - 1...
Page 167: Maintenance
Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE OILS: For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID: Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 168 MAINTENANCE GUIDES TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: Inspect the air cleaner clogging monitor frequently to see if the air cleaner is clogged. Clean the air cleaner element at a shorter interval than specified. Clean the radiator core frequently to avoid clogging.
Page 169: 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. 4 - 4...
Page 170 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 171 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 172: 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 173: Wear Parts
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 174: 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 175: 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 Transmission Hydraulic Cooling (front and Pins Fuel tank case system system rear) (each) Capacity Liters – Specified US gal 11.1 18.5 75.0 20.6...
Page 176: 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 177: 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 178: Periodic Replacement Of Safety Critical Parts
These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance.
Page 179 MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q'ty Replacement interval Fuel hose (fuel tank - fuel strainer) Fuel hose (fuel strainer - injection pump) Fuel return hose (injection pump - fuel tank) Fuel hose (injection nozzle - fuel filter) Fuel spill hose (engine output connector - fuel tank) Steering hose (pump - steering valve) Steering hose (steering valve - steering cylinder)
Page 180: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) REPLACE TRANSMISSION OIL FILTER ELEMENT 4- 52 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT 4- 61 WHEN REQUIRED CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT 4- 18 CLEAN INSIDE OF COOLING SYSTEM...
Page 181 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 500 HOURS SERVICE REPLACE ADDITIONAL FUEL FILTER CARTRIDGE 4- 48 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 50 REPLACE TRANSMISSION OIL FILTER ELEMENT 4- 52 LUBRICATE CENTER DRIVE SHAFT SPLINE 4- 53 CHECK FAN BELT FOR WEAR 4- 53...
Page 182: Service Procedure
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE INITIAL 250 HOURS SERVICE Perform the following maintenance only after the first 250 hours. Replace transmission oil filter element Replace hydraulic tank filter element For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS and 2000 HOURS SERVICE.
Page 183: 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 184 MAINTENANCE SERVICE PROCEDURE CLEANING OR REPLACING OUTER ELEMENT 1. Remove lock (1) of the cover, then remove cover (2). 2. Remove outer element (4). 3. Clean the air cleaner body interior and the cover. 4. Direct dry compressed air (less than 0.69 MPa (7 kg/ cm , 99.4 PSI)) to the element from inside along its folds, then direct it from outside along its folds and again from inside.
Page 185 MAINTENANCE SERVICE PROCEDURE REPLACING INNER ELEMENT 1. First remove the outer element, and then remove the inner element. 2. Cover the air connector side (outlet side) with a clean cloth or tape. 3. Clean the inside of the air cleaner body, then remove the cover installed in Step 2. 4.
Page 186: 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 187 MAINTENANCE SERVICE PROCEDURE When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing table given below. It is actually better to estimate and temperature about 10°C (18°F) lower when deciding the mixing ratio. The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (antifreeze/total amount of coolant x 100).
Page 188 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 3. Set a container in position to catch the drain antifreeze mixture, then open the drain valve (3) at the radiator lower tank and drain plug (4) of the engine, and drain the coolant. 4.
Page 189: Check Transmission Oil Level, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK TRANSMISSION OIL LEVEL, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. Carry out this procedure if there is any sign of oil on the transmission case, or if there is oil mixed with the cooling water.
Page 190 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE (1)When check- User 1)Run at idling for Method of ing after leav- operating at least 15 checking ing at idling continuous minutes, then level at (when heat is ly (check leave idling balanced in during 2)Check when whole trans-...
Page 191: Check Axle Oil Level, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK AXLE OIL LEVEL, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. Perform this procedure if there is any sign of oil on the axle case. Inspect the machine on a horizontal surface.
Page 192: Check Window Washing Fluid Level, Add Fluid
MAINTENANCE SERVICE PROCEDURE CLEAN AXLE CASE BREATHER 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. When cleaning the breather, clean the breathers at two places (front and rear).
Page 193: Clean Radiator Fins And Oil Cooler Fins
MAINTENANCE SERVICE PROCEDURE CLEAN RADIATOR FINS AND OIL COOLER FINS WARNING If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the compressed air, high-pressure water, or steam, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment. Carry out this procedure if there is any mud or dirt stuck to the radiator or oil cooler.
Page 194: Check Electrical Intake Air Heater
MAINTENANCE SERVICE PROCEDURE 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 repaired or checked for dirt or disconnections. REPLACE BUCKET TEETH WARNING It is dangerous if the work equipment moves by mistake when the tooth is being replaced.
Page 195 MAINTENANCE SERVICE PROCEDURE ONE-PIECE TOOTH When the bucket teeth are worn, replace them as follows. 1. Raise the bucket to a suitable height, then put blocks under the bucket to keep the bottom of the bucket horizontal. 2. Remove the bolt and nuts (1) and (2), then remove bucket tooth (3).
Page 196: Replace Bucket Tooth With Segment Edge
MAINTENANCE SERVICE PROCEDURE REPLACE BUCKET TOOTH WITH SEGMENT EDGE WARNING It is dangerous if the work equipment moves by mistake when the tooth is being replaced. Set the work equipment in a stable position, stop the engine, then set the safety lock for the work equipment control lever securely to the LOCK position.
Page 197: Turn, Replace Bolt-On Cutting Edge
MAINTENANCE SERVICE PROCEDURE TURN, REPLACE BOLT-ON CUTTING EDGE WARNING It is extremely dangerous if the work equipment moves when carrying out the turning or replacement operation. Set the work equipment in a stable position, stop the engine, then set the safety lock lever for the work equipment control lever securely to the LOCK position.
Page 198: 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 199: 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 200: 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 201 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 202: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For the following items, see "CHECK BEFORE STARTING (PAGE 3-38)". Check machine monitor Check coolant level, add coolant Check oil level in engine oil pan, add oil Check fuel level, add fuel Check electric wiring Check parking brake Check brake pedal Check inflation pressure of tires...
Page 203: Every 50 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE 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. 4 - 38...
Page 204: 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 (3 places) 1. Using a grease pump, pump in grease through the grease fittings marked by the arrows. 2.
Page 205: Clean Element In Air Conditioner Fresh Air Filter
MAINTENANCE SERVICE PROCEDURE CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask. If the air conditioner has been used, the air filter should be cleaned. Stop the air conditioner before cleaning the element.
Page 206: 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 - 41...
Page 207 If water is added to above the bottom tip of the sleeve, use a pipette to remove electrolyte. Neutralize the removed electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your Komatsu distributor or your 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 208: Check Parking Brake
V-groove. If any abnormality is found, ask your Komatsu distributor for replacement of the pulley. If the V-belt is so lengthened that it cannot be adjusted any more or if it has any cuts or cracks, replace it.
Page 209: Check Air Conditioner Compressor Belt Tension, Adjust
MAINTENANCE SERVICE PROCEDURE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST CHECKING The standard deflection between the air conditioner compressor pulley and drive pulley when pressed with a thumb (approx. 58.8 N (6 kg)) should be approx. 8.5 to 11 mm (0.35 to 0.4 in). CHECK WHEN CHANGING THE V-BELT The standard deflection between the air conditioner compressor pulley and drive pulley when pressed with a thumb (approx.
Page 210: Clean Element In Air Conditioner Recirculation Filter
MAINTENANCE SERVICE PROCEDURE CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER 1. Open the filter inspection cover, remove the filter cover, then remove the filter in the direction of the arrow. When removing the filter to the side, put your weight on the seat, and push down.
Page 211 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE (1) Bucket pin (2 places) (2) Bucket link pin (2 places) (3) Tilt lever pin (1 place) (4) Dump cylinder rod end (1 place) 4 - 46...
Page 212 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE (5) Lift cylinder pin (4 places) (6) Lift arm pivot pin (2 places) (7) Dump cylinder bottom pin (1 place) (8) Steering cylinder bottom pin (2 places) (9) Steering cylinder rod end (2 places) 4 - 47...
Page 213: Every 500 Hours Service
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 214 MAINTENANCE SERVICE PROCEDURE 8. Remove filter cartridge cap (A) and install to the filter holder. 9. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
Page 215: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
3. Place a container to catch the oil under drain plug (P). 4. Loosen drain plug (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 plug (P).
Page 216 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 10. After replacing the filter cartridge, add engine oil through oil filler port (F) until the oil level is between the H and L marks on the dipstick. 11. Run the engine at idle for short time, then stop the engine, and check that the oil is between the H and L marks on the dipstick.
Page 217: Replace Transmission Oil Filter Element
MAINTENANCE SERVICE PROCEDURE REPLACE TRANSMISSION OIL FILTER ELEMENT WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before cleaning the engine breather. When using compressed air, there is a hazard that dirt may be blown up and cause serious injury. Always use safety glasses, dust mask, or other protective equipment.
Page 218: Lubricate Center Drive Shaft Spline
MAINTENANCE SERVICE PROCEDURE LUBRICATE CENTER DRIVE SHAFT SPLINE (1 place) 1. Using a grease pump, pump in grease through the grease fittings marked by the arrows. 2. After greasing, wipe off any old grease that was pushed out. CHECK FAN BELT FOR WEAR Check the V-belt and when the following conditions exist, replace or adjust the V-belt.
Page 219: Every 1000 Hours Service
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 220 MAINTENANCE SERVICE PROCEDURE 7. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it up 1/2 to 3/4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten to the correct amount.
Page 221: Change Oil In Transmission Case, Clean Strainer
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER 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 222: Clean Transmission Case Breather
MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 8. Pour in the specified amount of engine oil from oil filler (F). 9. After filling with oil, check that the oil is at the specified level. For details, see "CHECK TRANSMISSION OIL LEVEL, ADD OIL (PAGE 4-24)".
Page 223 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE (3) Front drive shaft (3 places) (4) Rear drive shaft (3 places) (5) Center drive shaft (3 places) (6) Upper drive shaft (2 places) 4 - 58...
Page 224: Check Tightening Parts Of Turbocharger
(9) Fan pulley (1 place) (10) Tension pulley (1 place) CHECK TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked. REPLACE CORROSION RESISTOR CARTRIDGE 1. Open the engine side cover located on the right of the engine hood.
Page 225: Clean Fuel Strainer
MAINTENANCE SERVICE PROCEDURE CLEAN FUEL STRAINER 1. Remove plug (1), then remove the strainer together with the plug. 2. Remove the dirt stuck to the strainer and strainer case, then wash with clean diesel oil or flushing oil. If the strainer is damaged, replace it with a new part.
Page 226: 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 227 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 8. Remove mounting bolts (4) of filter cover (3) at one place at the top of the tank, then remove the cover. When the cover is removed, the force of spring (5) may make the cover fly off, so keep the cover pushed down when removing the bolts.
Page 228: 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 229: Change Axle Oil
MAINTENANCE SERVICE PROCEDURE CHANGE AXLE OIL WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns.Wait for the temperature to go down before starting the work. When removing the plug, oil may spurt out, so turn the plug slowly to release the internal pressure, then remove it carefully. Refill capacity (front and rear, each): 78 liters (20.6 US gal) 1.
Page 230: Replace Element In Air Conditioner Recirculation Air Filter, Fresh Air Filter
MAINTENANCE MAINTENANCE SERVICE PROCEDURE 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 drain the oil. 4. After draining the oil, clean drain plugs (2), (3) and (4), then install them.
Page 231: Clean Engine Breather Element
(1). 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 232: Check Accumulator Function
Check the exhaust gas color visually. If there is any abnormality in the exhaust gas color, please contact your Komatsu distributor for inspection or replacement. For details of the action to take if there is an abnormality, see ENGINE (PAGE 3-102) "Exhaust gas occasionally turns black".
Page 233: Every 4000 Hours Service
If any abnormality is found, please contact your Komatsu distributor for replacement of the parts. CHECK FAN PULLEY AND TENSION PULLEY Check for play of the pulley and leakage of grease. If any problem is found, please contact your Komatsu distributor. CHECK AIR CONDITIONER COMPRESSOR, ADJUST As special tool is required for checking and adjusting the parts, request Komatsu distributor for service.
Page 234: Checking For Missing Fuel Spray Prevention Cap, Hardening Of Rubber
Check for any missing fuel spray prevention caps (1) to (16) or fuel spray prevention cover (17), and check also for any hardened rubber portions. If there are any missing caps or cover or the rubber is hardened, please contact your Komatsu distributor for repairs. Install rubber caps (1) to (10) with the slit facing the cylinder block.
Page 235: Every 8000 Hours Service
Maintenance for every 50, 100, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time. REPLACE HIGH-PRESSURE PIPING CLAMP Ask your Komatsu distributor to carry out this work. REPLACE FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor to carry out this work.
Page 236 5 - 1...
Page 237: Specifications
Normal load kg (lb) 8,100 (17860) Bucket capacity (with tip tooth) (cu.yd) 4.3 (5.6) Engine model – Komatsu SA6D140E-3 diesel engine Flywheel horsepower kW(HP)/rpm 235 (316)/2,100 A Overall length (without tooth) mm (ft in) 9,055 (29' 8") B Overall height mm (ft in) 3,815 (12' 6")
Page 238 6 - 1...
Page 239: Attachments, Options
(Rock) The displayed travel speed changes according to the tire size, so when installing optional tires, please contact your Komatsu distributor. On jobsites where there are boulders or sharp rocks, install tire protectors (mesh chain). Check the chain for cuts or sagging before starting operation.
Page 240: Handling E.c.s.s.(Electronic Controlled Suspension System)
ATTACHMENTS, OPTIONS HANDLING E.C.S.S.(ELECTRONIC CONTROLLED SUSPENSION SYSTEM) HANDLING E.C.S.S.(ELECTRONIC CONTROLLED SUSPENSION SYSTEM) Always read this section before using the E.C.S.S. in order to enable you to use it safely and effectively. METHOD OF OPERATING E.C.S.S. The E.C.S.S. switch is on the left side of the main panel. When the E.C.S.S.
Page 241: Precautions When Handling Accumulator
Do not make holes, weld it, or cut it with a gas cutter. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be removed. Please ask your Komatsu distributor to carry out this operation. REMOVAL OF E.C.S.S. PIPING Do not remove the piping or parts of the E.C.S.S..
Page 242: Handling Auto-Greasing System
HANDLING AUTO-GREASING SYSTEM With this system, the grease is automatically supplied through the conmputer controls. If any abnormality occurs in the lubrication controller, please inform your Komatsu distributor of the symptoms and ask for repairs to be carried out. METHOD OF OPERATING AUTO-GREASING SYSTEM 1.
Page 243 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM HANDLING AUTO-GREASING SYSTEM Remaining number of times of greasing If the remaining number of times of greasing is less than 10, remaining number is displayed and it flashes. If the remaining number of times is 10 or more, only the flashing is shown without displaying the number.
Page 244 For example, if the machine is used at temperatures below -20°C (-4°F), set the greasing time to 20 minutes (code No. 7). In addition, use lithium-based grease No. 0. When changing the set value, please consult your Komatsu distributor. METHOD OF SETTING When setting the various items, the value is not input directly.
Page 245 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM HANDLING AUTO-GREASING SYSTEM 4. Press the LEVEL and ITEM keys at the same time to set to the setting mode. 5. Press the ITEM key one or more times to select the item to be set.
Page 246 REPLACEMENT OF GREASE CARTRIDGE WARNING Air bleeding of pump involves danger because of high pressure. Ask your Komatsu distributor for air bleeding. Be careful of the force applied by spring (2) installed inside the cover. NOTICE After replacing cartridge,make sure to reset number counter on controller.
Page 247: Precautions When Handling Auto-Greasing System
ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM HANDLING AUTO-GREASING SYSTEM 3. Detach cap (5) and middle plug (6) from new grease cartridge and tightly screw it in. Screw in tightly to ensure that no air enters. 4. When fixing, if grease cartridge is pressed slightly and grease comes out and deposits in a heaped shape, and if grease cartridge is screwed into suction port connector under above conditions,no air will enter.
Page 248: Troubleshooting
ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM TROUBLESHOOTING If any abnormality occurs in the greasing system, the error codes will flash alternately to display the type of abnormality. Error code Item Cause Remedy E → a Defective Air in main piping Run pump as necessary and release pressurizing of grease from end of piping to bleed air pump...
Page 249: Handling Remote Positioner
ATTACHMENTS, OPTIONS HANDLING REMOTE POSITIONER HANDLING REMOTE POSITIONER This device is equipped with a remote positioner device. With this device, it is possible from the operator's seat to set the stopping position of the lift arm as desired and to slow down and stop the lift arm. This is designed to increase the operating efficiency and to reduce operator fatigue.
Page 250: Method Of Operating Remote Positioner
ATTACHMENTS, OPTIONS HANDLING REMOTE POSITIONER METHOD OF OPERATING REMOTE POSITIONER 1. When RAISE/LOWER selector switch (1) is pressed, the system is turned ON, the stop display lamp lights up, and the remote positioner is set to the actuation condition. REMARK Each time the RAISE/LOWER selector switch is pressed, the lighting of the display lamp changes as follows.
Page 251: Method Of Setting Remote Positioner Stop Position
2 again, and check that the condition in Step 3 is correct (the set lamps light up for 2 seconds and then go out). ADJUSTING REMOTE POSITIONER When the lift arm has been removed or the setting does not work efficiently, please contact your Komatsu distributor for adjustment. 6 - 14...
Page 252: Handling Joystick Steering System
ATTACHMENTS, OPTIONS HANDLING JOYSTICK STEERING SYSTEM HANDLING JOYSTICK STEERING SYSTEM STRUCTURE AND FUNCTION OF JOYSTICK STEERING The joystick steering system is a system used to steer wheel loaders with a lever instead of a steering wheel. The joystick enables steering with small, light movements, and helps to reduce operator fatigue.
Page 253 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING JOYSTICK STEERING SYSTEM HANDLING JOYSTICK STEERING SYSTEM *1 Manual switch Press the push button switch to turn OFF/ON. 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 254 ATTACHMENTS, OPTIONS HANDLING JOYSTICK STEERING SYSTEM Work with joystick and steering wheel CAUTION The forward and reverse directions of the transmission cannot be switched (from the directional lever to the FNR button on the joystick when the joystick ON/OFF switch is ON, or from the FNR button on the joystick to the directional lever when the joystick ON/OFF switch is OFF) if the directional lever and FNR button on the joystick are not both at the neutral position.
Page 255: Operation Method Of Joystick Steering System
ATTACHMENTS, OPTIONS HANDLING JOYSTICK STEERING SYSTEM OPERATION METHOD OF JOYSTICK STEERING SYSTEM CAUTION When operating with joystick lever (4), always adjust the angle of the steering wheel so that it is possible to see the FNR display on the machine monitor.
Page 256 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING JOYSTICK STEERING SYSTEM HANDLING JOYSTICK STEERING SYSTEM 8. Select the forward or reverse direction of the transmission with FNR button (6) on joystick head (4). Button N: Neutral (Transmission is set to the neutral position at the moment when this button is pushed.) Button F: Forward (Transmission is set to the forward position at the...
Page 257: Precautions For Steering With Joystick
Before starting the operation of the machine 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 machine before it is repaired completely.
Page 258: Adjustment Of Joystick Console
ATTACHMENTS, OPTIONS HANDLING JOYSTICK STEERING SYSTEM ADJUSTMENT OF JOYSTICK CONSOLE WARNING Stop the machine on level ground in a safe place when carrying out the adjustment. Carry out the adjustment before starting operations or when changing operator shifts. Put your back against the backrest of the operator's seat and adjust the seat so that it is possible to depress the brake fully, then adjust the console.
Page 259 ATTACHMENTS, OPTIONS HANDLING JOYSTICK STEERING SYSTEM ADJUSTMENT AIR-SUSPENSION SEAT (A) Fore-and-aft adjustment Pull lever (1) up, set the seat to the desired position, then release the lever. Fore-and-aft adjustment: 180 mm (7.1 in) (18 mm (0.71 in) x 10 stages) (B) Adjusting seat angle Move lever (2) up and push down on the rear of the seat to tilt it backward.
Page 260 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING JOYSTICK STEERING SYSTEM HANDLING JOYSTICK STEERING SYSTEM (D) Adjusting reclining angle Move lever (4) up and move the seat backrest to the front or rear. Push your back against the backrest when carrying out this adjustment.
Page 261: Handling Joystick
ATTACHMENTS, OPTIONS HANDLING JOYSTICK HANDLING JOYSTICK Normally, two control levers are used to operate the bucket and lift arm, but with the joystick, the bucket and lift arm can both be operated with the same lever. This makes operation easier because it means that there is no need to switch between levers when carrying out operations.
Page 262 ATTACHMENTS, OPTIONS HANDLING JOYSTICK OPERATING LIFT ARM Position (a): RAISE When the lift arm control lever is pulled further from the RAISE position, the lever is stopped in this position until the lift arm reaches the preset position of the kickout, and the lever is returned to the HOLD position.
Page 263 ATTACHMENTS, OPTIONS HANDLING JOYSTICK HOLD SWITCH To lock the speed range when traveling in automatic transmission, press switch (3) at the side of the joystick knob. The speed range displayed in the transmission indicator of the main monitor is held, and the HOLD display lights up.
Page 264: Handling Air-Suspension Seat
ATTACHMENTS, OPTIONS HANDLING AIR-SUSPENSION SEAT HANDLING AIR-SUSPENSION SEAT SEAT ADJUSTMENT WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. Adjust the seat position at the beginning of each shift or when operators change. Adjust the seat so that the brake pedal can be depressed all the way down with the operator's back against the backrest.
Page 265 ATTACHMENTS, OPTIONS HANDLING AIR-SUSPENSION SEAT (E) Seat height adjustment Move lever (2) up/down, then move the seat up or down as desired. Since lever (2) is also used for adjusting seat angle, set the seat to the desired height while adjusting the angle. Adjustment range: 60 mm (2.4 in) (F) Adjusting headrest height Move the headrest up and down to the desired height.
Page 266: Car Radio
ATTACHMENTS, OPTIONS CAR RADIO CAR RADIO EXPLANATION OF COMPONENTS Power switch/Volume Preset button Tone control knob SEEK Display Band selector switch Clock button/Displaying frequency Tuning switch POWER SWITCH/VOLUME When this switch (1) is turned to the right, it clicks and the power is turned on.
Page 267 ATTACHMENTS, OPTIONS CAR RADIO TONE CONTROL KNOB If this knob (2) is turned to the right, the high tone is emphasized; if it is turned to the left, the high tone is reduced. DISPLAY This display (3) shows the radio reception frequency and the operating mode.
Page 268 ATTACHMENTS, OPTIONS CAR RADIO PRESET BUTTON With this switch (6), each button can be set to one station each for FM and MW (AM). (For details of the method of resetting, see "METHOD OF SETTING PRESET BUTTONS (PAGE 6-33)".) SEEK When this switch (7) ("SEEK") is pressed, it automatically searches for stations that can be received, and when it receives a station, it stops.
Page 269: Method Of Use
ATTACHMENTS, OPTIONS CAR RADIO METHOD OF USE LISTENING TO RADIO 1. This switches on power (1) for the radio. 2. "BAND" switch (2) is used to select MW (AM) or FM. 3. Use the preset switch or tuning switch (3) to select the station. 4.
Page 270 ATTACHMENTS, OPTIONS CAR RADIO METHOD OF SETTING PRESET BUTTONS 1. Select the desired preset station. Use the "BAND" button to select MW (AM) or FM, and use the "TUNE" button to select the frequency of the broadcasting station. 2. Decide the number of the button to be preset, and keep it pressed for 2 seconds.
Page 271: Precautions When Using
ATTACHMENTS, OPTIONS CAR RADIO ADJUSTING TIME 1. Turn the radio power ON. If the display shows the frequency, set the CLOCK button to the time display. 2. To set the time, keep the CLOCK button pressed and Press the button to change the minutes Press the button to change the hours PRECAUTIONS WHEN USING...
Page 272: Am/Fm Radio-Cassette Stereo
ATTACHMENTS, OPTIONS AM/FM RADIO-CASSETTE STEREO AM/FM RADIO-CASSETTE STEREO 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 273 ATTACHMENTS, OPTIONS AM/FM RADIO-CASSETTE STEREO 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 274 ATTACHMENTS, OPTIONS AM/FM RADIO-CASSETTE STEREO 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 275 ATTACHMENTS, OPTIONS AM/FM RADIO-CASSETTE STEREO 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 276 ATTACHMENTS, OPTIONS AM/FM RADIO-CASSETTE STEREO 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 277: Method Of Operation
ATTACHMENTS, OPTIONS AM/FM RADIO-CASSETTE STEREO METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS To listen to a preset station, use band selector button (1) to select AM, FM1, or FM2, then press the preset switch number to listen to the desired station. It is possible to preset six AM stations and 12 FM stations (FM1: 6, FM2: 6).
Page 278 ATTACHMENTS, OPTIONS AM/FM RADIO-CASSETTE STEREO LISTENING TO RADIO 1. Turn the starting switch ON, then turn power switch (1) ON. 2. Set band selector button (2) to AM or FM. 3. Select the station with the preset buttons or manual tuning button (3).
Page 279: Precautions For Use
ATTACHMENTS, OPTIONS AM/FM RADIO-CASSETTE STEREO REVERSING TAPE When listening to the tape, press both FAST FORWARD, REWIND buttons (A) and (B) at the same time lightly. When this is done, the tape direction display will be reversed. PRECAUTIONS FOR USE Stow the antenna when traveling in places with low overhead clearance.
Page 280: Air Conditioner
ATTACHMENTS, OPTIONS AIR CONDITIONER AIR CONDITIONER GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL Fan switch FRESH/RECIRC selector switch Air conditioner switch Temperature control switch Mode selector switch FAN SWITCH This switch (1) can be used to adjust the airflow in four stages. It also acts as the main switch for the air conditioner.
Page 281 ATTACHMENTS, OPTIONS AIR CONDITIONER 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 282 ATTACHMENTS, OPTIONS AIR CONDITIONER 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 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.
Page 283: Method Of Operation
ATTACHMENTS, OPTIONS AIR CONDITIONER 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 284 ATTACHMENTS, OPTIONS AIR CONDITIONER COOL BOX When the cooling is being used, this can be used for keeping drinks and other things cool. When the heating is being used, it can be used to keep things warm. When using the box, open the vent grill. When not using the box, close the grill.
Page 285: Handling Brake Cooling System
ATTACHMENTS, OPTIONS HANDLING BRAKE COOLING SYSTEM HANDLING BRAKE COOLING SYSTEM An air-cooled oil cooler is installed to improve the cooling efficiency for the brake cooling oil (axle oil). For machines equipped with the brake cooling system, carry out the following inspection and maintenance. WHEN REQUIRED CHECK AXLE OIL LEVEL, ADD OIL WARNING...
Page 286 ATTACHMENTS, OPTIONS HANDLING BRAKE COOLING SYSTEM CLEAN AXLE CASE BREATHER 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. When cleaning the breather, clean the breathers at two places (front and rear).
Page 287: Every 2000 Hours Service
ATTACHMENTS, OPTIONS HANDLING BRAKE COOLING SYSTEM EVERY 2000 HOURS SERVICE REPLACE AXLE OIL AND BRAKE COOLING OIL FILTER CARTRIDGE This is a standard operation for the EVERY 2000 HOURS SERVICE, but if the brakes squeal, change the oil at shorter intervals. When changing the axle oil, replace the brake cooling oil filter cartridge at the same time.
Page 288 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING BRAKE COOLING SYSTEM HANDLING BRAKE COOLING SYSTEM 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 drain the oil.
Page 290: Index
INDEX INDEX <A> FUSE 3- 33 ADJUSTING WORK EQUIPMENT POSTURE 3- 71 <G> AIR CONDITIONER 6- 43 GENERAL PRECAUTIONS 2- 13 GENERAL LOCATIONS AND GENERAL VIEW FUNCTION OF CONTROL PANEL 6- 43 GENERAL VIEW OF CONTROLS AND METHOD OF OPERATION 6- 46 GAUGES AM/FM RADIO-CASSETTE STEREO...
Page 291 AND LUBRICANT DIRECTIONS OF MACHINE RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR <L> PRODUCTS OTHER THAN LOADING, UNLOADING WORK 3- 81 KOMATSU GENUINE OIL 4- 11 LOCKING 3- 78 USE OF FUEL, COOLANT AND LONG-TERM STORAGE 3- 90 LUBRICANTS ACCORDING TO AFTER STORAGE...
Page 292 INDEX <T> TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR TORQUE LIST 4- 12 TOWING PIN 3- 32 TRANSPORTATION 3- 81 TRANSPORTATION PROCEDURE 3- 81 TROUBLESHOOTING 3- 91 IF BATTERY IS DISCHARGED 3- 96 METHOD OF TOWING MACHINE 3- 92 OTHER TROUBLE 3- 99 WHEN MACHINE RUNS OUT OF FUEL...

Komatsu Avance WA500-3 Operation & Maintenance Manual

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