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SERIAL NUMBERS H50051 AND UP

DANGER
Incorrect operation and maintenance of this machine
may be hazardous and cause injuries. The operator and
maintenance personnel must read this manual before
commencing operation or maintenance. Keep this
manual within reach at all times and ensure that
operating personnel read it at regular intervals.

NOTE
Komatsu has had the operating and maintenance
instructions translated into all the languages of the
European Union. Should you require a copy in another
language please inquire at your local dealer’s.

© 2006 Komatsu Hanomag GmbH

All Rights Reserved
Printed in Europe 03-2006
FOREWORD
11
 FOREWORD

1-2
FOREWORD FOREWORD

FOREWORD 0.
This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre-
cautions in this manual must be followed at all times when performing operation and maintenance. Most accidents
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci-
dents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and
maintenance.

WARNING
Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.
Always be sure to read and understand this manual thoroughly before performing operation and
maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thor-
oughly and be sure that you understand them fully.
Keep this manual at 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 immedi-
ately from Komatsu or your Komatsu distributor.

If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operat-
ing the machine.

Storage location for the Operation and Maintenance

Manual:
Pocket (1) at rear of operator’s seat

1-3
FOREWORD FOREWORD

EU DIRECTIVES 0.

Machines supplied by us fulfil the Directive for Machinery 89/392/EEC and all supplements. If the machine is being
used in another country, it is possible that certain safety regulations and specifications may not be fulfilled for use
in that country. For example, priority vehicle warning lamps may be used in some countries, but are forbidden in
others.
Please contact our dealer before using the machine if you have any questions regarding the fulfilment of standards
and regulations in a specific country.

Notes on subsequent installation of electrical and electronic equipment and components

Electrical and electronic equipment and/or components which have been installed subsequently, emit electromag-
netic radiation which can influence the function of the electronic components and sections of the machine. This
can have an influence on the safety of the machine and endanger persons. For this reason, please ensure that the
following safety instructions are observed.
If you are installing electrical or electronic equipment and/or components in the machine and connect them to the
vehicle electrical system, you must check at own responsibility that the installations do not cause any disturbance
to the vehicle’s electronic system or other components. Above all, you must ensure that any subsequently installed
electrical and electronic components comply with the EMV Directive 89/336/EEC in its current edition and bear the
CE mark.
The following requirements also have to be met for subsequent installation of mobile communication systems (e.g.
radio, telephone):
Only equipment approved by national legislation (e.g. BZT approval for Germany) may be used
The unit must be fixed in position
Portable or mobile units may only be used inside the vehicles if they are connected to a fixed outside
antenna
The transmitter unit must be spatially separated from the vehicle’s electronic system
Make sure when installing the antenna that this is installed correctly with good earth connection between
antenna and vehicle mass
Also observe Komatsu and machine manufacturer’s installation instructions for wiring, installation and maximum
permitted power consumption.

1-4
FOREWORD SAFETY INFORMATION

SAFETY INFORMATION 0.
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 situa-
tions.

Signal words

The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury. This signal word is to be limited to most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
erate injury. It may also be used to alert against unsafe practices.

Example of safety message using signal word

WARNING
When standing up from the operator’s seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the levers when they are not locked, this may cause a serious injury or damage.

Other signal words

In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is are useful to know.

NOTICE This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
REMARKS This word is used for information that is useful to know.

1-5
SAFETY INFORMATION FOREWORD

Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
For details of safety labels, see "SAFETY LABELS (2-2)".

Safety labels using pictogram

Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condi-
tion at the top or left side, and the method of avoiding the haz-
ardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Komatsu cannot predict every circumstance that might involve
a potential hazard in operation and maintenance. Therefore,
the safety messages in this manual and on the machine may
not include all possible safety precautions.
If any procedures or actions not specifically recommended or
allowed in this manual are used, it is your responsibility to take
the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions
described in this manual.

The explanations, values, and illustrations in this manual were

prepared based on the latest information available at that time.
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.

The numbers in circles in the illustrations correspond to the

numbers in ( ) in the text. (For example: M -> (1))

1-6
FOREWORD INTRODUCTION

INTRODUCTION 0.
This loader is a machine with independent transmission, moving on chains or wheels. Driving in forward direction,
the loader can load or dig material using its attachments intended for loading operations (i.e. bucket).
The standard operation cycle of a loader includes filling up and loading of the bucket, transporting the material and
emptying the bucket.

INTENDED USE 0.
If you use the machine for any other purpose than specified above, we will not accept any responsibility for safety.
All considerations concerning safety will then be up to the owner or the operating and maintenance personnel. In
any case, neither you nor any other person are/is authorised to perform work and functions explicitly prohibited in
these operating instructions.
The transport of persons in the work equipment is strictly forbidden!
For details of the operating procedure, see “WORKING POSSIBILITY (3-96)“.

DIRECTIONS OF MACHINE 0.

Front

Bucket

Left Right

Rear

In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.

1-7
NECESSARY INFORMATION FOREWORD

NECESSARY INFORMATION 0.
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.

PIN/MACHINE SERIAL NO. PLATE AND POSITION 0.

On the center right of the front frame.

GK015035GB

ENGINE SERIAL NO. PLATE AND POSITION 0.

This name plate is affixed on the oil cooler at the side of engine cylinder block on the left side of machine.

EPA: Environmental Protection Agency, U.S.A.

1-8
FOREWORD NECESSARY INFORMATION

ROPS/FOPS-CAB SERIAL NO. PLATE 0.

This plate is located on the right inside cab on the rear beam.

AXLE SERIAL NO. PLATE 0.

This plate is located on the right of front axle and on the left of rear axle.

TRANSMISSION SERIAL NO. PLATE 0.

This plate is located in travel direction front, above the transmission output.

SEAT OPERATOR SERIAL NO. PLATE 0.

This plate is located in front of seat, covered by the bellows.

1-9
NECESSARY INFORMATION FOREWORD

POSITION OF SERVICE METER 0.

It is at the center bottom of the machine monitor.

For details of the service meter display, see SERVICE METER

in EXPLANATION OF COMPONENTS “SERVICE METER (3-
8)“.

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 0.

Machine serial No.

Engine serial No.
Distributor name
Address

Service Personnel
Phone/Fax

1-10
FOREWORD CONTENTS

CONTENTS 0.

FOREWORD
FOREWORD........................................................................................................................................................ 1-3

SAFETY INFORMATION..................................................................................................................................... 1-5

INTRODUCTION.................................................................................................................................................. 1-7
INTENDED USE ........................................................................................................................................ 1-7
DIRECTIONS OF MACHINE ..................................................................................................................... 1-7

NECESSARY INFORMATION ............................................................................................................................ 1-8

PIN/MACHINE SERIAL NO. PLATE AND POSITION ............................................................................... 1-8
ENGINE SERIAL NO. PLATE AND POSITION......................................................................................... 1-8
ROPS/FOPS-CAB SERIAL NO. PLATE.................................................................................................... 1-9
AXLE SERIAL NO. PLATE ........................................................................................................................ 1-9
TRANSMISSION SERIAL NO. PLATE ...................................................................................................... 1-9
SEAT OPERATOR SERIAL NO. PLATE................................................................................................... 1-9
POSITION OF SERVICE METER ........................................................................................................... 1-10
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ........................................................................... 1-10

CONTENTS ....................................................................................................................................................... 1-11

DIMENSIONS, WEIGHTS AND OPERATING DATA ....................................................................................... 1-19

WA380-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA .......................................................... 1-19

CE-CONFORMING EQUIPMENT...................................................................................................................... 1-20

CE-CONFORMING EQUIPMENT ........................................................................................................... 1-20
MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT
421-93-H1900 .......................................................................................................................................... 1-21

SAFETY
SAFETY LABELS................................................................................................................................................ 2-2
LOCATION OF SAFETY LABELS ............................................................................................................. 2-2
SAFETY LABELS ...................................................................................................................................... 2-3

GENERAL PRECAUTIONS ................................................................................................................................ 2-4

PRECAUTIONS FOR OPERATION .................................................................................................................. 2-12

STARTING ENGINE ................................................................................................................................ 2-12
OPERATION............................................................................................................................................ 2-13

TRANSPORTATION.......................................................................................................................................... 2-19

BATTERY .......................................................................................................................................................... 2-20

TOWING ............................................................................................................................................................ 2-22

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CONTENTS FOREWORD

PRECAUTIONS FOR MAINTENANCE ............................................................................................................. 2-23

PRECAUTIONS WITH TIRES ........................................................................................................................... 2-30

OPERATION
GENERAL VIEW ................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE ................................................................................................................ 3-2
GENERAL VIEW OF CONTROLS AND GAUGES.................................................................................... 3-3

EXPLANATION OF COMPONENTS................................................................................................................... 3-6

MACHINE MONITOR ................................................................................................................................ 3-6
TYPES OF WARNING...................................................................................................................... 3-7
CENTRAL WARNING LAMP ............................................................................................................ 3-7
CHARACTER DISPLAY PORTION .................................................................................................. 3-8
EMERGENCY STOP ITEM ............................................................................................................ 3-14
CAUTION ITEMS............................................................................................................................ 3-16
INSPECTION AND MAINTENANCE ITEM..................................................................................... 3-19
PILOT DISPLAY PORTION ............................................................................................................ 3-23
METER DISPLAY PORTION.......................................................................................................... 3-28
OTHER FUNCTIONS OF MACHINE MONITOR............................................................................ 3-30
SWITCHES .............................................................................................................................................. 3-34
CONTROL LEVERS, PEDALS ................................................................................................................ 3-47
STEERING TILT LOCK LEVER............................................................................................................... 3-52
CAP WITH LOCK..................................................................................................................................... 3-53
CAP WITH LOCK FOR THE FUEL TANK FILLER PORT.............................................................. 3-53
CAP WITH LOCK FOR THE HYDRAULIC TANK FILLER PORT .................................................. 3-54
SAFETY BAR........................................................................................................................................... 3-55
TOWING PIN ........................................................................................................................................... 3-55
GREASE PUMP....................................................................................................................................... 3-55
CAB DOOR OPEN LOCK ........................................................................................................................ 3-56
CAB WINDOW OPEN LOCK................................................................................................................... 3-56
BACKUP ALARM ..................................................................................................................................... 3-56
FUSE ....................................................................................................................................................... 3-57
FUSE CAPACITY AND NAME OF CIRCUIT.................................................................................. 3-57
SLOW-BLOW FUSE ................................................................................................................................ 3-58
TAKING OFF POWER............................................................................................................................. 3-59
AIR CONDITIONER................................................................................................................................. 3-60
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ............................................... 3-60
METHOD OF OPERATION ............................................................................................................ 3-62
PRECAUTIONS WHEN USING ..................................................................................................... 3-63
CAB WIPER............................................................................................................................................. 3-64
PREVENTING DAMAGE TO WIPER ARM BRACKET .................................................................. 3-64
DUST INDICATOR .................................................................................................................................. 3-64

OPERATION...................................................................................................................................................... 3-65
CHECK BEFORE STARTING ................................................................................................................. 3-65

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FOREWORD CONTENTS

WALK-AROUND CHECK ............................................................................................................... 3-65

CHECK BEFORE STARTING ........................................................................................................ 3-67
ADJUSTMENT BEFORE STARTING...................................................................................................... 3-72
OPERATIONS BEFORE STARTING ...................................................................................................... 3-75
STARTING ENGINE ................................................................................................................................ 3-77
NORMAL STARTING ..................................................................................................................... 3-77
STARTING IN COLD WEATHER ................................................................................................... 3-79
CHECKS AFTER STARTING .................................................................................................................. 3-81
BREAKING IN THE MACHINE....................................................................................................... 3-81
NORMAL OPERATION .................................................................................................................. 3-81
STOPPING ENGINE................................................................................................................................ 3-83
CHECKS AFTER STOPPING ENGINE.......................................................................................... 3-83
MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING .......................................................... 3-84
PREPARATIONS FOR MOVING MACHINE.................................................................................. 3-84
CHANGING GEAR SPEED ..................................................................................................................... 3-87
CHANGING DIRECTION......................................................................................................................... 3-88
STOPPING MACHINE............................................................................................................................. 3-90
TRANSMISSION CUT-OFF..................................................................................................................... 3-91
TURNING................................................................................................................................................. 3-93
EMERGENCY STEERING ............................................................................................................. 3-93
OPERATION OF WORK EQUIPMENT ................................................................................................... 3-95
WORKING POSSIBILITY ........................................................................................................................ 3-96
DIGGING OPERATIONS................................................................................................................ 3-96
LEVELING OPERATIONS.............................................................................................................. 3-99
PUSHING OPERATION ................................................................................................................. 3-99
LOAD AND CARRY OPERATIONS ............................................................................................... 3-99
LOADING OPERATIONS ............................................................................................................. 3-100
PRECAUTIONS FOR OPERATION ...................................................................................................... 3-102
PERMISSIBLE WATER DEPTH................................................................................................... 3-102
IF WHEEL BRAKE DOES NOT WORK........................................................................................ 3-102
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES........................................................ 3-102
PRECAUTIONS REGARDING BRAKE FUNCTION .................................................................... 3-103
ADJUSTING WORK EQUIPMENT ........................................................................................................ 3-104
ADJUSTING BOOM KICKOUT .................................................................................................... 3-104
ADJUSTING BUCKET POSITIONER........................................................................................... 3-105
BUCKET LEVEL INDICATOR ...................................................................................................... 3-105
PARKING MACHINE ............................................................................................................................. 3-106
CHECKS AFTER WORK ....................................................................................................................... 3-108
LOCKING............................................................................................................................................... 3-108
HANDLING THE TIRES......................................................................................................................... 3-109
PRECAUTIONS WHEN HANDLING TIRES................................................................................. 3-109
TIRE PRESSURE......................................................................................................................... 3-109
PRECAUTIONS FOR USING LOAD AND CARRY METHOD ..................................................... 3-110

TRANSPORTATION........................................................................................................................................ 3-111
TRANSPORTATION PROCEDURE...................................................................................................... 3-111
LOADING, UNLOADING WORK WITH TRAILERS ..................................................................... 3-111
LOADING...................................................................................................................................... 3-111

1-13
CONTENTS FOREWORD

SECURING MACHINE ................................................................................................................. 3-112

UNLOADING ................................................................................................................................ 3-112
LIFTING MACHINE................................................................................................................................ 3-113
LOCATION OF LIFTING POSITION MARK ................................................................................. 3-114
WEIGHT TABLE ........................................................................................................................... 3-114
LIFTING PROCEDURE ................................................................................................................ 3-115

COLD WEATHER OPERATION ..................................................................................................................... 3-116

LOW TEMPERATURE........................................................................................................................... 3-116
FUEL AND LUBRICANTS ............................................................................................................ 3-116
COOLANT .................................................................................................................................... 3-116
BATTERY ..................................................................................................................................... 3-117
AFTER COMPLETION OF WORK ........................................................................................................ 3-117
AFTER COLD WEATHER ..................................................................................................................... 3-117
WARMING-UP OF STEERING HYDRAULIC ........................................................................................ 3-118

LONG-TERM STORAGE................................................................................................................................. 3-119

BEFORE STORAGE.............................................................................................................................. 3-119
DURING STORAGE .............................................................................................................................. 3-119
AFTER STORAGE................................................................................................................................. 3-119

TROUBLESHOOTING..................................................................................................................................... 3-120
WHEN MACHINE RUNS OUT OF FUEL .............................................................................................. 3-120
TOWING THE MACHINE ...................................................................................................................... 3-121
WHEN ENGINE CAN BE USED................................................................................................... 3-121
WHEN ENGINE CANNOT BE USED ........................................................................................... 3-122
RELEASING PARKING BRAKE ................................................................................................... 3-122
EMERGENCY TRAVEL OPERATION ......................................................................................... 3-124
BATTERY IS DISCHARGED ................................................................................................................. 3-125
REMOVAL AND INSTALLATION OF BATTERY ......................................................................... 3-125
PRECAUTIONS FOR CHARGING BATTERY ............................................................................. 3-126
STARTING ENGINE WITH BOOSTER CABLE ........................................................................... 3-126
OTHER TROUBLE ................................................................................................................................ 3-128
ELECTRICAL SYSTEM ................................................................................................................ 3-128
CHASSIS ...................................................................................................................................... 3-129
ENGINE ........................................................................................................................................ 3-131

MAINTENANCE
GUIDES TO MAINTENANCE .............................................................................................................................. 4-3

OUTLINES OF SERVICE .................................................................................................................................... 4-5

OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ........................................................................ 4-5
OIL .................................................................................................................................................... 4-5
FUEL................................................................................................................................................. 4-5
COOLANT ........................................................................................................................................ 4-5
GREASE ........................................................................................................................................... 4-5
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ................................................................... 4-6

1-14
FOREWORD CONTENTS

STORING OIL AND FUEL................................................................................................................ 4-6

FILTERS ........................................................................................................................................... 4-7
BIODEGRADABLE HYDRAULIC OIL AND LUBRICANTS .............................................................. 4-7
OUTLINE OF ELECTRIC SYSTEM........................................................................................................... 4-7

WEAR PARTS ..................................................................................................................................................... 4-8

WEAR PARTS LIST................................................................................................................................... 4-8

LUBRICANTS AND OPERATING MEANS......................................................................................................... 4-9

LUBRICATION CHART ............................................................................................................................. 4-9
LUBRICANTS, FUELS AND FILLING CAPACITIES ............................................................................... 4-10

STANDARD TIGHTENING TORQUES ............................................................................................................. 4-12

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ......................................................................... 4-13

MAINTENANCE SCHEDULE CHART .............................................................................................................. 4-15

MAINTENANCE SCHEDULE CHART..................................................................................................... 4-15

SERVICE PROCEDURE ................................................................................................................................... 4-17

INITIAL 50 HOURS SERVICE ................................................................................................................. 4-17
INITIAL 250 HOURS SERVICE ............................................................................................................... 4-17
INITIAL 1000 HOURS SERVICE ............................................................................................................. 4-17
WHEN REQUIRED .................................................................................................................................. 4-18
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT ......................................................... 4-18
CLEAN INSIDE OF COOLING SYSTEM ....................................................................................... 4-21
CHECK WATER SEPARATOR ...................................................................................................... 4-24
CHECK TRANSMISSION OIL LEVEL, ADD OIL ........................................................................... 4-25
CHECK AXLE OIL LEVEL, ADD OIL.............................................................................................. 4-26
CLEAN AXLE CASE BREATHER .................................................................................................. 4-27
CLEAN CONDENSER OF AIR CONDITIONER............................................................................. 4-27
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID............................................................ 4-28
CLEAN RADIATOR FINS AND COOLER FINS ............................................................................. 4-28
CHECK ELECTRICAL INTAKE AIR HEATER ............................................................................... 4-31
REPLACE BOLT ON CUTTING EDGE .......................................................................................... 4-31
REPLACE BUCKET TEETH........................................................................................................... 4-32
CHECK AIR CONDITIONER .......................................................................................................... 4-33
REPLACE SLOW-BLOW FUSE ..................................................................................................... 4-34
SELECTION AND INSPECTION OF TIRES .................................................................................. 4-35
CHECK BEFORE STARTING ................................................................................................................. 4-37
EVERY 50 HOURS SERVICE ................................................................................................................. 4-38
DRAIN WATER, SEDIMENT FROM FUEL TANK.......................................................................... 4-38
EVERY 100 HOURS SERVICE ............................................................................................................... 4-38
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL................................................................... 4-38
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER .................................................. 4-39
EVERY 250 HOURS SERVICE ............................................................................................................... 4-40
CHECK BATTERY ELECTROLYTE LEVEL .................................................................................. 4-40
CHECK PARKING BRAKE............................................................................................................. 4-42
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST .................................... 4-42

1-15
CONTENTS FOREWORD

CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN .................................................................. 4-43

CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER ........................................ 4-43
EVERY 500 HOURS SERVICE ............................................................................................................... 4-44
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ................... 4-44
REPLACE FUEL FILTER CARTRIDGE ......................................................................................... 4-45
EVERY 1000 HOURS SERVICE ............................................................................................................. 4-46
CHANGE TRANSMISSION OIL AND FILTER, CLEAN STRAINER .............................................. 4-46
CLEAN TRANSMISSION CASE BREATHER ................................................................................ 4-47
CHECK TIGHTENING PARTS OF TURBOCHARGER.................................................................. 4-47
CHECK PLAY OF TURBOCHARGER ROTOR.............................................................................. 4-47
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT................................... 4-47
REPLACE CORROSION RESISTOR CARTRIDGE ...................................................................... 4-47
EVERY 2000 HOURS SERVICE ............................................................................................................. 4-48
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT..................... 4-48
REPLACE HYDRAULIC TANK BREATHER ELEMENT ................................................................ 4-50
CHANGE AXLE OIL ....................................................................................................................... 4-51
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR
FILTER ........................................................................................................................................... 4-51
CLEAN PPC CIRCUIT STRAINER................................................................................................. 4-52
CLEAN ENGINE BREATHER ELEMENT ...................................................................................... 4-52
CHEK ALTERNATOR, STARTING MOTOR .................................................................................. 4-52
CHECK ENGINE VALVE CLEARANCE, ADJUST ......................................................................... 4-52
CLEAN AND CHECK TURBOCHARGER ...................................................................................... 4-52
CHECK INJECTOR ........................................................................................................................ 4-53
CHECK ACCUMULATOR GAS PRESSURE ................................................................................. 4-53
CHECK VIBRATION DAMPER ...................................................................................................... 4-53
CHECK BRAKE DISC WEAR......................................................................................................... 4-54
EVERY 4000 HOURS SERVICE ............................................................................................................. 4-55
LUBRICATING................................................................................................................................ 4-55
CHECK WATER PUMP .................................................................................................................. 4-55
CHECK AIR CONDITIONER COMPRESSOR, ADJUST ............................................................... 4-56
REPLACE INJECTOR NOZZLE TIP .............................................................................................. 4-56
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER ..... 4-56
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER ...... 4-56
EVERY 8000 HOURS SERVICE ............................................................................................................. 4-57
REPLACE HIGH-PRESSURE PIPING CLAMP ............................................................................. 4-57
REPLACE FUEL SPRAY PREVENTION CAP ............................................................................... 4-57

TECHNICAL DATA
TECHNICAL DATA ............................................................................................................................................. 5-2

NOISE EMISSION LEVELS ................................................................................................................................ 5-4

VIBRATION LEVELS .......................................................................................................................................... 5-4

OPERATING CONDITION: ............................................................................................................. 5-4
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ............................................................. 5-4

1-16
FOREWORD CONTENTS

LIMIT VALUES FOR SLOPES ............................................................................................................................ 5-6

ATTACHMENTS, OPTIONS
HANDLING LOAD METER ................................................................................................................................. 6-2
GENERAL LOCATIONS ............................................................................................................................ 6-2
MACHINE MONITOR WITH LOAD METER..................................................................................... 6-2
SWITCHES....................................................................................................................................... 6-3
LOAD METER FUNCTIONS...................................................................................................................... 6-4
HANDLING LOAD METER DISPLAY........................................................................................................ 6-7
SETTING ADDITION MODE ............................................................................................................ 6-7
SETTING REMAIN MODE ............................................................................................................... 6-9
TOTAL LOAD DATA DISPLAY....................................................................................................... 6-12
STOPPING CALCULATION ........................................................................................................... 6-14
CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY ................................... 6-15
CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED................................. 6-17
SUBTRACTION FUNCTION .......................................................................................................... 6-20
METHOD OF SETTING TIME ON CLOCK ............................................................................................. 6-22
PRINTER OUTPUT ................................................................................................................................. 6-24
PRINTOUT MODE.......................................................................................................................... 6-24
METHOD OF SELECTING PRINTOUT MODE.............................................................................. 6-25

HANDLING TORQUE CONVERTER LOCK-UP............................................................................................... 6-27

GENERAL LOCATIONS .......................................................................................................................... 6-27
METHOD OF OPERATION ..................................................................................................................... 6-28
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED........................................................................... 6-29

HANDLING AUTOMATIC AIR-CONDITIONER ................................................................................................ 6-30

GENERAL LOCATIONS AND FUNCTIONS OF CONTROL PANEL ...................................................... 6-30
METHOD OF OPERATION ..................................................................................................................... 6-34
PRECAUTIONS WHEN USING............................................................................................................... 6-36
INSPECTION AND MAINTENANCE ....................................................................................................... 6-36

CENTRAL LUBRICATION ................................................................................................................................ 6-37

OPERATION............................................................................................................................................ 6-37
DISPLAY AND CONTROL UNIT ............................................................................................................. 6-38
LED-DISPLAY ................................................................................................................................ 6-38
PUSHBUTTONS............................................................................................................................. 6-38
CHANGING THE LUBRICATION INTERVAL TIMES.............................................................................. 6-39

HANDLING MULTIFUNCTION LEVER............................................................................................................. 6-40

EXPLANATION OF COMPONENTS ....................................................................................................... 6-40
WORK EQUIPMENT LEVER ......................................................................................................... 6-41
DIRECTIONAL SELECTOR SWITCH ............................................................................................ 6-42
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH ....................................................... 6-42
DIRECTIONAL SELECTOR PILOT LAMP ..................................................................................... 6-43
OPERATION............................................................................................................................................ 6-44
USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE...................................... 6-44

1-17
CONTENTS FOREWORD

KICKDOWN SWITCH ..................................................................................................................... 6-46

HOLD SWITCH............................................................................................................................... 6-46

JOYSTICK STEERING SYSTEM ...................................................................................................................... 6-47

COMPONENTS ....................................................................................................................................... 6-47
SHIFT UP, SHIFT DOWN SWITCHES........................................................................................... 6-47
F-N-R SWITCH ............................................................................................................................... 6-48
JOYSTICK STEERING LEVER ...................................................................................................... 6-48
JOYSTICK ON/OFF SWITCH ........................................................................................................ 6-48
HI/LOW SELECTOR SWITCH ....................................................................................................... 6-48
HORN SWITCH .............................................................................................................................. 6-49
CONSOLE LOCK LEVER............................................................................................................... 6-49
HEIGHT ADJUSTMENT LOCK LEVER ......................................................................................... 6-49
ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER ....................................................................... 6-49
STRUCTURE AND FUNCTION............................................................................................................... 6-49
GETTING IN OR OUT ............................................................................................................................. 6-51
ADJUSTMENT OF JOYSTICK CONSOLE.............................................................................................. 6-51
OPERATION METHOD OF JOYSTICK STEERING SYSTEM ............................................................... 6-52

EPC WORK EQUIPMENT LEVER .................................................................................................................... 6-55

OPERATIONAL FEATURES ................................................................................................................... 6-55
SWITCHES .............................................................................................................................................. 6-55
SAFETY LOCK LEVER (FOR WORK EQUIPMENT LEVER) ........................................................ 6-56
SEMI AUTO DIGGING OPERATIONS .................................................................................................... 6-57
SEMI AUTO DIGGING OPERATIONS ........................................................................................... 6-57
METHOD OF OPERATION ............................................................................................................ 6-57
SELECTING DIGGING PATTERN ................................................................................................. 6-57
MANUAL OPERATION DURING AUTOMATIC CONTROL........................................................... 6-57
END OF CONTROL........................................................................................................................ 6-58
METHOD OF REMOTE POSITIONER .................................................................................................... 6-58
REMOTE POSITIONER RAISE MODE SWITCH........................................................................... 6-58
REMOTE POSITIONER LOWER MODE SWITCH ........................................................................ 6-58
REMOTE POSITIONER RAISE/LOWER SET SWITCH ................................................................ 6-59
METHOD OF OPERATION ............................................................................................................ 6-59

INDEX
INDEX .................................................................................................................................................................. 7-3

NOTES
NOTES ................................................................................................................................................................. 8-2

1-18
FOREWORD DIMENSIONS, WEIGHTS AND OPERATING DATA

DIMENSIONS, WEIGHTS AND OPERATING DATA 0.

WA380-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA 0.

d
a
c
H
b

F
e
E B
D A
C WA380-5Abm

Measurements, operating data

Bucket capacity to ISO 7546 m³ 3,1
Material density t/m³ 1,8
Bucket weight without teeth kg 1.380
Static tipping load, straight kg 15.310
Static tipping load, 40° angle kg 13.605
Breakout force, hydraulic kN 164
Lifting capacity, hydraulic, on ground kN 182
Operating weight *) kg 17.765
a Reach at 45° discharge mm 1.080
b Dumping height at 45° discharge mm 2.970
c Lift height, hinge pin mm 4.076
d Height to upper edge of bucket mm 5.450
e Digging depth mm 90
A Overall length, bucket on ground mm 8.120
B Wheel base mm 3.300
C Bucket width mm 2.926
These values refer to machines with 23:5 R25
D Width over tyres mm 2.695
L3
E Gauge mm 2.160
F Ground clearance mm 449
*) Machine without additional counterweight
H Overall height mm 3.374

1-19
CE-CONFORMING EQUIPMENT FOREWORD

CE-CONFORMING EQUIPMENT 0.
CE-CONFORMING EQUIPMENT 0.

CE-conforming equipment

1 2 3 4 5 –

Load Hydraulic
Volume Weight
Type Part No. Capacity pressure
m³ kg
kg bar

423-70-H2060 4.50 8,100 - -

423-70-H2100 3.10 5,580 - 1,383

423-70-H2110 3.10 5,580 - 1,478

423-70-H2120 3.25 5,850 - 1,594

423-71-H2130 3.10 5,580 - 1,504

423-71-H2140 3.10 5,580 - 1,609

Bucket WA380-5H 423-71-H2150 3.25 5,850 - 1,725

423-71-H2160 3.45 6,210 - 1,656

423-71-H2170 3.45 6,210 - 1,781

423-71-H2180 3.60 6,480 - 1,876

423-71-H2190 3.00 5,400 - 1,687

423-71-H2200 3.00 5,400 - 1,790

423-71-H2210 3.20 5,760 - 1,910

1
2
3
4
5

GK032012

1-20
FOREWORD CE-CONFORMING EQUIPMENT

MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING

TO DOCUMENT 421-93-H1900 0.
The responsibility for observing valid regulations in the case of wheel loaders with "interchangeable equipment"
(e.g. bucket or fork-lift) which was not supplied from works lies with the customer which was subsequently fitted to
the machine.
The directives for CE conformity and road-traffic registration are deemed to have been fulfilled when the manufac-
turer of the equipment confirms fulfilment of the form 421-93-H1900 alongside.
The certification must be sent to the customer and the wheel loader manufacturer. The CE conformity declaration
for a specific wheel loader is only legally valid once this has taken place.
The dimensions X1, X2, Y1 and Y2 must be provided by the customer for approval for use on public roads. (valid
in Germany)
The dimension Sh (smallest tyre radius) must be added to the dimension D2.
The figure G (in kg) represents the maximum load (equipment and operating load) which may act upon this point.

D2
Y2
X2

Sh
X1
Y1

A1
A2

Sh

GK100395b

1-21
CE-CONFORMING EQUIPMENT FOREWORD

1
B1
C1
2 D1

B2
D2

C2
H2
H1

Sh
J

A1
A2

d1=d2

3
Sh

b3

d2
3

d1
c
h

b4 b2

b1
GK100395

1-22
FOREWORD CE-CONFORMING EQUIPMENT

M A N U FA C T U R E R - S U P P L I E D C E - C O N F O R M I N G
EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900
WA380-5H 421-93-H1900
A1 Distance: bucket pivoting point - front axle, horizontal A1 2,030 mm
A2 Distance: bucket pivoting point - front axle, vertical
A2 1,295 mm
Sh Distance: road level - front axle
B1 Distance: driver's eye (1) - front axle, horizontal Sh 741 mm
B2 Distance: driver's eye (1) - front axle, vertical
B1 2,050 mm
C1 Distance: centre steering wheel - centre front axle,
horizontal B2 2,175 mm
C2 Distance: center steering wheel - centre front axle,
C1 1,615 mm
vertical
D1 Distance: headlight - centre front axle, horizontal C2 1,775 mm
D2 Distance: headlight - centre front axle, vertical
D1 440 mm
G Weight of equipment and working load
H1 Distance: bucket pivoting point - bucket upper edge, verti- D2 1,686 mm
cal (carrying position)
G 7,170 mm
H2 Distance: bucket pivoting point - vision line, vertical (carry-
ing position) H1 1,399 mm
J Distance: road level - bucket bottom edge (carrying posi-
H2 1,632 mm
tion)
X1 Distance: cutter protection - front axle, horizontal J 270 mm
X2 Distance: cutter protection - road level, vertical
X1 2,586 mm
Y1 Distance: teeth protection - front axle, horizontal
Y2 Distance: teeth protection - road level, vertical X2 1,128 mm
b1 Bucket connection dimension, boom width inside Y1 2,738 mm
b2 Bucket connection dimension, boom arm
b3 Bucket connection dimension, tilt rod Y2 1,277 mm
b4 Bucket connection dimension, temporary size b1 992 mm
c Bucket connection dimension between d1 and d2, vertical
b2 108 mm
d1 Bucket connection dimension, bolt (3) for boom
d2 Bucket connection dimension, bolt (3) for tilt rod b3 116 mm
e Bucket connection dimension d1 - d2, horizontally dis-
b4 438 mm
placed
h Distance: bucket bottom edge - boom bolt hole c 387 mm
l Distance: centre of bolt -- centre of fastening screw
d1 85 mm

d2 85 mm

e 20 mm

h 220 mm
l 90 mm

1 Driver’s eye

2 vision line

3 Bolts

MICHELIN
Tyres
23.5R25 XHA

3,1 m³
Bucket
423-71-H2351

1-23
CE-CONFORMING EQUIPMENT FOREWORD

1-24
 SAFETY
12

WARNING
Please be sure that you fully understand this manual and the
precautions related to safety for the machine. When operat-
ing or servicing the machine, always follow these precaus-
tions strictly.
SAFETY LABELS SAFETY

SAFETY LABELS 0.
The following safety labels are used on this machine. Be sure that you fully understand the correct position and
content of these safety labels.

Always keep all safety labels clean. When cleaning them, use soap and water. Do not use organic solvents or gas-
oline. These may cause the safety labels to peel off.

Missing or damaged safety labels must be replaced. Order the new part from your Komatsu distributor.

LOCATION OF SAFETY LABELS 0.

The rear full fender is available as an option, so (8) indicates machines witch equipped with full fender.

2-2
SAFETY SAFETY LABELS

SAFETY LABELS 0.

1 Danger of explosion due to pressure accumulator 8 Do not stand on fender

P/N: 421-93-H1300 P/N: 421-93-H1400
2 Keep a safe distance to the bucket cylinder 9 Caution, hot water/oil
P/N: 421-93-H1380 P/N: 421-93-H1280
3 Keep a safe distance to the machine´s articulated 10 Use Komatsu oil only
joint
P/N: 421-93-H1320 P/N: 421-93-H1390
4 Secure articulated joint during transport or when 11 Keep a safe distance to the attachments
loading
P/N: 421-93-H1330 P/N: 421-93-H1370
5 Do not open when engine is running 12 Instructions prior to operation/maintenance
P/N: 09667-A0880 P/N: 421-93-H1840
6 Do not stand to close to the machine 13 Precautionary measures when leaving the machine
P/N: 421-93-H1360 P/N: 421-93-H1860
7 Caution when using jump leads 14 Only start machine from driver’s seat
P/N: 421-93-H1310 P/N: 0942-A0481
15 Safety measures before starting work
P/N: 421-93-H1850

421-93-H1840
421-93-H1860

421-93-H1850

9jm03988-2

2-3
GENERAL PRECAUTIONS SAFETY

GENERAL PRECAUTIONS 0.
SAFETY RULES 0.
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may
be severly impaired putting yourself and everyone else on your jobsite in danger.
When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-
stand all hand signals that are to be used.

IF ABNORMALITIES ARE FOUND 0.

If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the abnormality has been cor-
rected.

CLOTHING AND PERSONAL PROTECTIVE ITEMS 0.

Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other
protruding parts.
If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine,
so tie your hair up and be careful not to let it get caught.
Always wear a hard hat and safety shoes. If the nature of
the work requires it, wear safety glasses, mask, gloves, ear
plugs, and safety belt when operating or maintaining the
machine.
Check that all protective equipment functions properly
before using it.

FIRE EXTINGUISHER AND FIRST AID KIT 0.

The fire extinguisher is located on the rear cab frame on the
left inside the operator’s cab. Two fasteners are provided on
the lower left strut of the cab for fastening the fire extin-
guisher in place.
If, in the course of certain operations, there is danger of fire,
fire extinguishers must be at hand. Familiarise with the use
of the fire extinguishers.
Inform yourself on measures to be taken in the event of a
fire.
The first-aid kit is located in the compartment under the
driver's seat.
Make sure that you know all telephone numbers of the per-
sons that you need to contact in an emergency.

SAFETY FEATURES 0.
Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if
they are damaged.
Understand the method of use of safety features and use them properly.
Never remove any safety features. Always keep them in good operating condition.

2-4
SAFETY GENERAL PRECAUTIONS

KEEP MACHINE CLEAN 0.

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. Always keep the machine clean.

INSIDE OPERATOR’S COMPARTMENT 0.

When entering the operator’s compartment, always remove all mud and oil from the soles of your shoes.
If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious
accident.
Do not leave parts or tools lying around the operator’s compartment.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not use cellular telephones inside the operator’s compartment when driving or operating the machine.
Never bring any dangerous objects such as flammable or explosive items into the operator’s cab.

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT 0.

Before standing up from the operator’s seat to adjust the
operator’s seat, always lower the work equipment, set
safety lock lever (1) to the LOCK position and parking brake
switch (2) to the ON position, then stop the engine.
If you accidentally touch the travel or swing lever when they
are not locked. The work equipment may suddenly move Free
and cause serious injury.

Lock
1 9EA03583

When leaving the machine, always lower the work equip-

ment to the ground, set safety lock lever (1) to the LOCK
position and parking brake switch (2) to the ON position,
then stop the engine. Lock all places and always take the
key with you and leave it in the specified location.
ON

OFF

2-5
GENERAL PRECAUTIONS SAFETY

HANDRAILS AND STEPS 0.

To prevent personal injury caused by slipping or falling off the machine, always do as follows.
Use the handrails and steps marked by arrows in the dia-
gram on the right when getting on or off the machine.

To ensure safety, always face the machine and maintain

three-point contact (both feet and one hand, or both hands
and one foot) with the handrails and steps to ensure that
you support yourself.

When entering the cab, open the cab door, push the door
securely into catcher (1) to hold in position, then use the
handrail on the inside to get on the machine.
For details of the method of releasing the door lock, see
“CAB DOOR OPEN LOCK (3-56)“.
Do not grip the control levers when getting on or off the
machine.
Never climb on the engine hood or covers where there are
no non-slip pads.
Never move from the step at the rear of the machine or the
step at the side of the cab to stand on top of the tire.
Before getting on or off the machine, check the handrails
and steps, and if there is any oil, grease, or mud on them,
wipe it off immediately. In addition, repair any damage and
tighten any loose bolts.
Do not get on or off the machine while holding tools in your hand.

2-6
SAFETY GENERAL PRECAUTIONS

MOUNTING AND DISMOUNTING 0.

Never jump on or off the machine. Never get on or off a moving machine.
If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try
to stop it.

NO PEOPLE ON ATTACHMENTS 0.
Never let anyone ride on the work equipment, or other attachments. There is a hazard of falling and suffering seri-
ous injury.

DO NOT GET CAUGHT IN ARTICULATED PORTION 0.

If the clearance at the articulating portion changes, it will
lead to serious personal injury.
Do not allow anyone to come inside the articulation range.

Never enter or put your hand, arm, or any part of your body
in the movable portion between the work equipment and
machine or between the cylinder and the work equipment.
If someone operates the control levers by mistake, the gap
between the work equipment and machine and between the
cylinder and work equipment will change, and you, your
hand, or arm will be caught and you may suffer serious
injury.
If you have to go into a movable portion, always take action
to secure the work equipment and ensure that it cannot
move.

PREVENTION OF BURNS 0.
Hot coolant
To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to
a temperature where it is possible to touch the radiator cap
by hand before starting the operation. Even when the cool-
ant has cooled down, loosen the cap slowly to relieve the
pressure inside the radiator before removing the cap.

Hot oil
To prevent burns when checking or draining the oil, wait for
the oil to cool to a temperature where it is possible to touch
the plug by hand before starting the operation. Even when
the oil has cooled down, loosen the plug slowly to relieve
the internal pressure before removing the plug.

2-7
GENERAL PRECAUTIONS SAFETY

FIRE PREVENTION 0.
Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particu-
larly flammable and can be hazardous. To prevent fire,
always observe the following:
Do not smoke or use any flame near fuel or oil.
Stop the engine before refueling.
Do not leave the machine while adding fuel or oil.
Tighten all fuel and oil caps securely.
Do not spill fuel on overheated surfaces or on parts of
the electrical system.
Use well-ventilated areas for adding or storing oil and
fuel.
Keep oil and fuel in the determined place and do not
allow unauthorized persons to enter.
After adding fuel or oil, wipe up any spilled fuel or oil.
When carrying out grinding or welding work on the chas-
sis, move any flammable materials to a safe place
before starting.
When washing parts with oil, use a non-flammable oil.
Diesel oil and gasoline may catch fire, so do not use
them.
Put greasy rags and other flammable materials into a
safe container to maintain safety at the work place.
Do not weld or use a cutting torch to cut any pipes or
tubes that contain flammable liquids.
Fire caused by accumulation of flammable material.
Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed
around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire.
Always keep electric wiring connections clean and securely tightened.
Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.
Fire coming from hydraulic line
Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the
hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.
Explosion caused by lighting equipment
When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with anti-
explosion specifications. If such lighting equipment is not used, there is danger of explosion that may cause
serious injury.
When taking the electrical power for the lighting from the machine itself, follow the instructions in this man-
ual.

ACTION IF FIRE OCCURS 0.

If a fire occurs, escape from the machine as follows.
Turn the start switch OFF to stop the engine.
Use the handrails and steps to get off the machine.

WINDOW WASHER LIQUID 0.

Use an ethyl alcohol base washer liquid. Methyl alcohol base washer liquid may irritate your eyes, so do not use it.

2-8
SAFETY GENERAL PRECAUTIONS

ROPS (Roll Over Protective Structure) 0.

The roll-over protection system (ROPS) protects the operator and absorbs load and impact energy, if the
machine should roll over.
The ROPS is a fixed component of the cab. The machine must not be operated without this roll-over protection
system.
The ROPS meets the regulations of all member states of the EU. If, however, the ROPS is modified, damaged,
or repaired without permission, its stability is impaired. In this case, the ROPS must be replaced, since its cor-
rect function can no longer be guaranteed.
The ROPS can only provide maximum protection, if the driver wears the safety belt correctly. For this reason,
the safety belt is to be worn when the machine is in operation.

ATTACHMENT FOR PROTECTION AGAINST FALLING OBJECTS (FOPS) 0.

When you work on a site where there is danger of falling rocks or other objects, the machines must be equipped
with a FOPS. If the FOPS is modified without permission or damaged, its stability is impaired. In this case, the
FOPS must be replaced, since its correct function can no longer be guaranteed.

PRECAUTIONS FOR ATTACHMENTS 0.

When installing optional parts or attachments, there may be problems with safety or legal restrictions, There-
fore contact your Komatsu distributor for advice.
Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.
When installing and using optional attachments, read the instruction manual for the attachment, and the gen-
eral information related to attachments in this manual.

UNAUTHORIZED MODIFICATION 0.
Any modification mode without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications
made without authorization from Komatsu.

SAFETY AT WORKSITE 0.
Before starting operations, thoroughly check the work area for dangerous working conditions.
Inspect the surface of the soil in the working area and determine the optimum and safest procedure.
Determine the required safety measures against dangers
on public roads in co-operation with the owners, users, and
responsible authorities.
On sites where there are underground water pipes, gas
pipes, or conduits for high voltage cables, contact the
responsible supply company to determine the lines’ posi-
tions. Ensure that these facilities will not be damaged.
When working with water or crossing sand banks, first
check the subsoil and depth and flow rate of the water.
Ensure that the permitted water depth will not be exceeded.
Take action to prevent unauthorized people from approach-
ing the jobsite.

WORKING ON LOOSE GROUND 0.

Do not drive the machine too close to edges of hills, overhangs, and deep ditches.
If the soil starts to sag at these locations, the machine may tip over, fall down, or roll over, thus injuring you
severely.
Take into account that the soil is wet and soft after heavy rainfall, or very loose after blasting.

2-9
GENERAL PRECAUTIONS SAFETY

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 0.

Do not travel or operate the machine near electric cables.
There is a hazard of electric shock, which may cause serious
injury or property damage. On jobsites where the machine may
go close to electric cables, always do as follows.
Before starting work near electric cables, inform the local
power company of the work to be performed, and ask them
to take the necessary action.

A0060820

Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death.
Always maintain a safe distance (see the table on the right)
Safety
between the machine and the electric cable. Check with the Nominal Voltage
Distance
local power company about safe operating procedure
before starting operations. up to 1000 V 1m
To prepare for any possible emergencies, wear rubber
shoes and gloves. Lay a rubber sheet on top of the seat, over 1 kV up to 110 kV 3m
and be careful not to touch the chassis with any exposed
part of your body. over 110 kV up to 220 kV 4m
Use a signalman to give warning if the machine approaches over 220 kV up to 380 kV 5m
too close to the electric cables.
When carrying out operations near high voltage cables, do with unknown nominal voltage 5m
not let anyone come close to the machine.
If the machine should come too close or touch the electric
cable, to prevent electric shock, the operator should not
leave the operator’s compartment until it has been con-
firmed that the electricity has been shut off.
Also, do not let anyone come close to the machine.

ENSURE GOOD VISIBILITY 0.

Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to
ensure that operations and travel can be carried out safely. Always do as follows.
Position a signalman if there are areas at the rear of the machine where the visibility is not good.
When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up
additional lighting in the work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.

VENTILATION FOR ENCLOSED AREAS 0.

Exhaust fumes from the engine can kill.
If it is necessary to start the engine within an enclosed area, or
when handling fuel, flushing oil, or paint, open the doors and
windows to ensure that adequate ventilation is provided to pre-
vent gas poisoning.

2-10
SAFETY GENERAL PRECAUTIONS

CHECKING SIGNALMAN’S SIGNALS AND SIGNS 0.

Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.

EMERGENCY EXIT FROM OPERATOR’S CAB 0.

Machines equipped with a cab have doors on the left and right sides. If the door on the one side does not open,
escape from the door on the other side.

BE CAREFUL ABOUT ASBESTOS DUST 0.

Asbestos dust in the air can cause lung cancer if it is inhaled.
There is danger of inhaling asbestos when working on jobsites
handling demolition work or work handling industrial waste.
Always observe the following:
Spray water to keep down the dust when cleaning.
Do not use compressed air for cleaning.
If there is danger that there may be asbestos dust in the air,
always operate the machine from an upwind position.
All workers should use an approved respirator.
Do not allow other persons to approach during the opera-
tion.
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.

2-11
PRECAUTIONS FOR OPERATION SAFETY

PRECAUTIONS FOR OPERATION 0.

STARTING ENGINE 0.
If there is a warning tag hanging from the work equipment con-
trol lever, do not start the engine or touch the levers (1).

9JA03034-A

CHECKS BEFORE STARTING ENGINE 0.

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.
Remove all dirt from the surface of the lens of the front lamps, working lamps, and rear combination lamp, and
check that they light up correctly.
Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and
check for damage to the electric wiring.
Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake
pedal, and check that the pedals work properly.
Adjust the operator’s seat to a position where it is easy to carry out operations, and check that there is no dam-
age or wear to the seat belt or mounting clamps.
Check that the gauges work properly, check the angle of the lights and working lamps, and check that the con-
trol levers are all at the neutral position.
Before starting the engine, make sure that the safety lock lever is in the LOCK position.
Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. See “ADJUST
REAR VIEW MIRROR (3-74)“.
Check that there are no persons or obstacles above, below, or in the area around the machine.

PRECAUTIONS WHEN STARTING 0.

When starting the engine, sound the horn as a warning.
Only start and operate the machine from the seat. Never try to start the engine by hot-wiring the ignition. This
can cause fire, grave injuries or death.
Do not allow anyone apart from the operator to ride on the machine.
Do not short circuit the starting motor circuit to start the engine. It is not only dangerous, but will also cause
damage to the equipment.
For machines equipped with a back-up alarm, check that the alarm works properly.

PRECAUTIONS IN COLD AREAS 0.

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.
There is a hazard that this will ignite the battery.

2-12
SAFETY PRECAUTIONS FOR OPERATION

Before charging or starting the engine with a different power source, melt the battery electrolyte and check for
frost and leakage of battery electrolyte before starting.

OPERATION 0.
CHECKS BEFORE OPERATION 0.
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 for any abnormality in the sound of the
machine,vibration, heat, smell, or gauges; check also that
there is no leakage of oil or fuel.
Check for any abnormality in the sound of the machine,
vibration, heat, smell, or gauges; check also that there is no
leakage of oil or fuel.
If any abnormality is found, carry out repairs immediately.

Before driving the machine or starting operations, check

that safety bar (1) is securely fixed at the FREE position.

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 0.

Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles.
Before travelling, sound the horn to warn people in the area.
Always operate the machine only when seated.
Do not allow anyone apart from the operator to ride on the machine.
Check that the back-up alarm (alarm buzzer when machine travels in reverse) works properly.
Always lock the door and windows of the operator’s compartment in position (open or closed).
On jobsites where there is a hazard of flying objects or of objects entering the operator’s compartment, check
that the door and windows are securely closed.
If there is an area to the rear of the machine which cannot
be seen, position a signal person. Take special care not to
hit other machines or people when turning or swinging the
machine.
Always be sure to carry out the above precautions even when
the machine is equipped with mirrors.

2-13
PRECAUTIONS FOR OPERATION SAFETY

PRECAUTIONS WHEN TRAVELING 0.

Never turn the key in the starting switch to the OFF position. It is dangerous if the engine stops when the
machine is traveling, because the steering becomes heavy. If the engine stops, depress the brake pedal imme-
diately to stop the machine.
When traveling on level ground, keep the work equipment at
height of 27 cm from the ground.
When traveling, do not operate the work equipment control
levers. If the work equipment control levers have to be oper-
ated, stop the machine first, then operate the levers.
When traveling on rough ground, travel at low speed and do
not operate the steering suddenly. There is danger that the
machine may turn over. The work equipment may hit the
ground surface and cause the machine to lose its balance,
or may damage the machine or structures in the area.
Avoid traveling over obstacles when possible. If the
machine has to travel over an obstacle, keep the work
equipment close to the ground and travel at low speed.
Never travel over obstacles which make the machine tilt
strongly to one side.
When traveling or carrying out operations, always keep a
safe distance from people, structures, or other machines to
avoid coming into contact with them.
When passing over bridges or structures, check first that the
structure is strong enough to support the weight of the
machine. When traveling on public roads, check first with
the relevant authorities and follow their instructions.
When operating in tunnels, under bridges, under electric
wires, or other places where the height is limited, operate
slowly and be extremely careful not to let the work equip-
ment hit anything.
Always obey the traffic regulations when traveling on public
roads. This machine travels at a lower speed than normal
automobiles, so keep to the side of the road and be careful
to leave the center of the road free for other vehicles.
If you drive the machine at high speed continuously for a
long time, the tires will overheat and the internal pressure
will become abnormally high. This may cause the tires to
burst. If a tire bursts, it produces an extremely large
destructive force, and this may cause serious injury or acci-
dent.
If you are going to travel continuously, please consult your
Komatsu distributor.

2-14
SAFETY PRECAUTIONS FOR OPERATION

TRAVELING ON SLOPES 0.
To prevent the machine from tipping over or slipping to the
side, always do as follows.

Keep the work equipment approx. 20 to 30 cm above the

ground. In case of emergency, lower the work equipment to
the ground immediately to help stop the machine.

Always travel straight up or down a slope. Traveling at an

angle or across the slope is extremely dangerous.
Do not turn on slopes or travel across slopes. Always go
down to a flat place to change the position of the machine,
then travel on to the slope again.
Travel on grass, fallen leaves, or wet steel plates with low
speed. Even with slight slopes there is a hazard that the
machine may slip.
If the engine stops, depress the brake pedal immediately,
lower the bucket to the ground, and apply the parking brake
to stop the machine.
When traveling downhill, never shift gear or place the trans-
mission at neutral. It is dangerous not to use the braking
force of the engine. Always place the transmission in a low
gear before starting to travel downhill.
When traveling downhill, travel slowly. If necessary, use the
braking force of the engine together with the brake pedal to
control the travel speed.
When traveling up or down hills with a loaded bucket,
always travel with the bucket facing uphill. If the machine
travels with the bucket facing downhill, there is danger that
the machine may tip over.

2-15
PRECAUTIONS FOR OPERATION SAFETY

PROHIBITED OPERATIONS 0.
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 opera-

tions, 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. The load may spill or the bucket may hit the
dump truck and cause serious injury or property damage.

EMERGENCY LOWERING SYSTEM 0.

When the engine is not running, you can lower the work unit by
means of the pilot control lever.
PPC control lever
To achieve this, slowly press the pilot control lever (2) forward
to the "LOWER" position.

9JA03282B

EPC control lever

1. Turn the key in ignition switch (1) to ON.
2. Then slowly press the pilot control lever (2) forward to the
"LOWER" position.
2
1

9JA03272B

Multifunction lever
Push the multifunction lever (3) slowly forward to the "LOWER" 3
position.

2-16
SAFETY PRECAUTIONS FOR OPERATION

PRECAUTIONS WHEN OPERATING 0.

When using the machine, to prevent the machine from overturning due to overloading and to avoid damage to
the work equipment, do not exceed the maximum permitted load or performance of the machine.
If the engine cannot be started again after it has stopped, immediately operate the work equipment control
levers to lower the work equipment to the ground. (After the engine stops, the accumulator allows the work
equipment to be operated for a limited time.)
Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or when
dropping soil over a cliff, dump one pile, then use the next pile of soil to push the first pile.
The load suddenly becomes lighter when the soil is pushed over a cliff or when the machine reaches the top of
a slope. When this happens, there is danger that the travel speed will suddenly increase, so be sure to reduce
the speed.
When the bucket is fully loaded, never start, turn, or stop the
machine suddenly. There is danger of the machine turning
over.

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.
When handling unstable loads, be careful not to raise the
work equipment too high or tip the bucket back too much.
If the work equipment is suddenly lowered or suddenly
stopped, the reaction may cause the machine to tip over.
Particularly when carrying a load, be sure to operate the
work equipment carefully.

When operating in tunnels, under bridges, under electric

wires, or other places where the height is limited, be
extremely careful not to let the work equipment hit anything.
To prevent accidents caused by hitting other objects, always
operate the machine at a speed which is safe for operation,
particular in confined spaces, indoors, and in places where
there are other machines.

METHODS OF USING BRAKE 0.

When the machine is traveling, do not rest your foot on the brake pedal. If you travel with your foot resting on
the pedal, the brake will always be applied, and this will cause the brakes to overheat and fail.
Do not depress the brake pedal repeatedly if not necessary.
When traveling downhill, use the braking force of the engine, and always use the right brake pedal at the same
time.

2-17
PRECAUTIONS FOR OPERATION SAFETY

OPERATE CAREFULLY ON SNOW 0.

When working on snow or ice-covered surfaces, there is danger of the machine starting to skid even at a very
flat angle. For this reason, drive slowly and avoid sudden starts, turns, or stops.
When driving on hill flanks covered with snow do not brake abruptly to stop the machine. To stop the machine,
lower the bucket onto the ground.
The load may vary considerably, depending on the structure of the snow. For this reason, reduce the load and
pay attention that the machine does not start to skid.
When traveling on snow-covered roads, always fit tire chains.

PARKING MACHINE 0.
Park the machine on firm, level ground.
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 posi-
tion, and stop the engine.
Lock all points that can be locked and store the key in a safe
place. Free

Lock

1 9EA03583

When parking the machine on public roads, ensure that it

does not obstruct traffic. Put up signal lamps and required
warning signs to ensure that passing traffic can clearly see
the machine.
Adhere to all regulations on parking vehicles and securing On
building sites.

Off

If it is necessary to park the machine on a slope, set blocks

under the wheels to prevent the machine from moving.

2-18
SAFETY TRANSPORTATION

TRANSPORTATION 0.
(See also “TRANSPORTATION (3-111)“).
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 0.

Loading and unloading is potentially dangerous. For this rea-
son, proceed with extreme care.
Load and unload the machine only on solid and level
ground. Keep a safety distance to the edge of the road.
Block the wheels of the transport vehicle and place support
Ramp
blocks under both ramps before driving the machine onto
the transport vehicle.
Only use ramps with appropriate carrying capacities and
widths. The ramps must be long enough to ensure that the Blocks
maximum loading gradient of 15° is not exceeded. Distance
Block
Ensure that the ramps are positioned and fastened safely between ramps
and that both sides have the same height. Set the distance
between the ramps to the distance between the wheel
tracks.
Ensure that the surfaces of the ramps are clean and free of
grease, oil, ice, and loose material. Remove any dirt adher-
ing to the wheels.
When loading and unloading the machine, keep the engine
speed low and drive slowly.
Do not carry out steering movements on the ramps. If
required, drive off the ramps again, correct alignment of the
machine, and drive up again.
After loading, i.e. when the machine is on the transport vehi-
cle, apply the parking brake.
Set the steering wheel of the machine to straight driving.
Secure the articulated steering with the safety bar.
Always secure the safety bar with the bolt and the spring
bolt in both positions.
Block the wheels of the machine with wheel chocks.
Secure the machine on the transport vehicle by means of
appropriate fastening equipment. Only use the attachment
points on the machine for lifting and securing. For safety Free
Lock
reasons, do not use any other points for fastening (e.g. axle,
cardan shaft, articulated steering, bucket teeth, or strapping
around the cab).

SHIPPING 0.
When shipping the machine on a trailer, adhere to all appli-
cable motor vehicle traffic regulations.
Determine the transport route, taking into account the width,
length, height, and weight of the load and, if necessary,
have this approved by the responsible authorities.

2-19
BATTERY SAFETY

BATTERY 0.
BATTERY HAZARD PREVENTION 0.
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. Always check the battery electrolyte level periodically and add distilled water to bring the
electrolyte level to the UPPER LEVEL line.
When working with batteries, always wear safety glasses and rubber gloves.
Never smoke or use any flame near the battery.

If you spill acid on your clothes or skin, immediately flush

the area with large amount of water.
If acid gets into your eyes, flush them immediately with
large amount of water and seek medical attention.
Before working with batteries, turn the starting switch to the
OFF position.

As there is a hazard that sparks will be generated, always do as follows:

Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.
Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last.
Attach the battery terminal securely.
Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
Tighten the battery caps securely.
Install the battery securely to the determined place.

2-20
SAFETY BATTERY

STARTING WITH BOOSTER CABLES 0.

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 opera-
tor’s seat and the other working with the battery).
When starting from another machine, do not allow the two
machines to touch.
When connecting the booster cables, turn the starting
switch OFF for both the normal machine and problem
machine. There is a hazard that the machine will move
when the power is connected.
Be sure to connect the positive (+) cable first when installing
the booster cables. Disconnect the negative (-) cable
(ground side) first when removing them.
When removing the booster cables, be careful not to let the
booster cable clips touch each other or to let the clips touch
the machine.
Always wear safety goggles and rubber gloves when start-
ing the engine with booster cables.
When connecting a normal machine to a problem machine
with booster cables, always use a normal machine with the
same battery voltage as the problem machine.
For details of the starting procedure when using booster
cables, see “STARTING ENGINE WITH BOOSTER CABLE
(3-126)“ in the OPERATION section.

2-21
TOWING SAFETY

TOWING 0.
WHEN TOWING 0.
Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selec-
tion or inspection of the wire rope.
For towing, see “TOWING THE MACHINE (3-121)“.
Always wear leather gloves when handling wire rope.
During the towing operation, never stand between the tow-
ing machine and the machine being towed.
Never tow a machine on a slope.

Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope
may break during the towing operation.

2-22
SAFETY PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS FOR MAINTENANCE 0.

WARNING TAG 0.
Always attach the “DO NOT OPERATE“ warning tag to work
equipment control lever (1) in the operator's cab to alert oth-
ers that you are performing service of maintenance on the
machine. Attach additional warning tags around the
machine if necessary.

9JA03034-A
Keep this warning tag in the tool box while it is not used. If
there is not the tool box, keep the tag in the operation man-
ual pocket.

If others start the engine, or touch or operate the work

equipment control lever while you are performing service or
maintenance, you could suffer serious injury or property
damage.

KEEP WORK PLACE CLEAN AND TIDY 0.

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances
that will cause you to slip. Always keep the work place clean the tidy to enable you to carry out operations safely. If
the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure yourself.

PERSONNEL 0.
Do not service or repair the machine unless you are an appropriately qualified technician or have been appro-
priately instructed by a qualified technician.
Do not allow unauthorized personnel into the dangerous area.
If necessary, employ a signal peson.

2-23
PRECAUTIONS FOR MAINTENANCE SAFETY

MAINTENANCE WITH ENGINE RUNNING 0.

Stop the machine on firm, level ground.
Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground and
stop the engine.

After shut-down of the engine, push the right hydraulic lever

(1) or the multifunction lever (A) 2 to 3 times to its stop to 1 A
the LIFT and LOWER position, in order to reduce the pres-
sure in the hydraulic circuit. Then push the safety lever (2)
to the LOCK position.

Free

Lock

Turn parking brake switch (3) to the ON position to apply the

parking brake, then put blocks under the front and rear of
the tires.

ON

OFF

Lock the front and rear frames with safety bar (4).

Free
Lock

2-24
SAFETY PRECAUTIONS FOR MAINTENANCE

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 0.

To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with
the engine running, carry out the operation with at least two workers and do as follows.
One worker must always sit in the operator’s seat and be
ready to stop the engine at any time. All workers must
maintain contact with the other workers.
Never drop or insert tools or other objects into the fan or fan
belt. Parts may break or be sent flying.
When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts,
so be extremely careful.

Set safety lock lever (1) to the LOCK position to prevent the
work equipment from moving.
Turn parking brake switch (2) to the ON position to apply the
parking brake.
Do not touch any control levers. If any control lever must be
Free
operated, give a signal to the other workers to warn them to
move to a safe place.

Lock

1 9EA03583

ON

OFF

INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF 0.

For machines equipped with a E.C.S.S. lower the bucket to the ground, turn the E.C.S.S. switch OFF, and stop the
engine before starting inspection or maintenance. NEVER turn the switch ON during inspection or maintenance.

PROPER TOOLS 0.
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.

2-25
PRECAUTIONS FOR MAINTENANCE SAFETY

HANDLING OF PRESSURE ACCUMULATORS 0.

WARNING
Danger of injury! Pressure accumulator is filled with highly
pressurised nitrogen.
Do not open or damage the pressure accumulator.

Always observe the following precautions.

Immediately inform your Komatsu dealer, if you detect mal-
functions or defects of pressure accumulators.
Filling pressure accumulators with gas or topping up gas in
pressure accumulators is strictly limited to persons autho-
rised to handle highly pressurised gas.
Do not hit against the pressure accumulator.
Keep naked light and sources of heat away from pressure
accumulators.
Do not drill holes into the pressure accumulator.
Do not weld parts to the pressure accumulator.
The service technicians must depressurise the hydraulic
system before they can remove the pressure accumulators.
The service technician must let the gas escape before they
can disassemble the pressure accumulator.

ATTACHMENTS 0.

CAUTION
Risk of injury!

Appoint a leader before starting removal or installation oper-

ations for attachments.
Place attachments that have been removed from the
machine in a stable condition so that they do not fall. And
take steps to prevent unauthorized persons from entering
the storage area.

2-26
SAFETY PRECAUTIONS FOR MAINTENANCE

WORKING UNDER THE RAISED BOOM 0.

WARNING
Danger of injury! The raised boom may suddenly fall! For
safety reasons, a raised boom must be secured against
dropping before you pass or stand under it.

The boom must be secured against moving if any work is to

be carried out under it when it is in a raised position. For this
purpose you should use a supporting prop (1) which is to be
positioned below the boom.
Park the machine on level, solid ground.
Apply the parking brake.
Place wheel chocks in front of the wheels to prevent the
machine from inadvertently rolling away.
Lift the arm far enough to allow the supporting prop to be
placed beneath the boom.
Switch off the engine.
With the engine switched off, lower the boom slowly until it
rests on the supporting prop.
Set the control lever to "NEUTRAL" and secure it with the
safety lever (2) (locked).

Free

Lock
2 9EA03583-1

2-27
PRECAUTIONS FOR MAINTENANCE SAFETY

PRECAUTIONS WHEN USING HAMMER 0.

When using a hammer, pins may fly out or metal particles may
be scattered. This may lead to serious injury. Always do as
follows.
If hard metal parts such as pins, bucket teeth, cutting edges,
or bearings are hit with a hammer, there is a hazard that
pieces might be scattered and cause injury. Always wear
safety goggles and gloves.
When hitting pins or bucket teeth, there is a hazard that bro-
ken pieces might be sent flying and injure people in the sur-
rounding area. Always check that there is no one in the
surrounding area.
If pins are hit with strong force, there is a hazard that the pin
may fly out and injure people in the surrounding area.

REPAIR WELDING 0.
Welding operations must always be carried out by a qualified welder and in a place equipped with a proper equip-
ment. There is a hazard of fire or electrocution when carrying out welding, so never allow any unqualified person-
nel to carry out welding.

REMOVING BATTERY TERMINAL 0.

When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of
the battery to prevent the flow of current.

PRECAUTIONS WITH HIGH-PRESSURE OIL 0.

The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always
check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to
serious injury or property damage, so always do as follows.
When carrying out inspection and maintenance of the pressure, release the pressure before starting. For
details, see “MAINTENANCE WITH ENGINE RUNNING (2-24)“. Do not carry out inspection or replacement
work with the circuit under pressure.
If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the pip-
ing and hoses and for swelling in the hoses.
When carry out inspection, wear safety glasses and leather gloves.
There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause blindness if it con-
tacts your eyes directly. If you are hit by a jet of high-pres-
sure oil and suffer injury to your skin or eyes, wash the
place with clean water, and consult a doctor immediately for
medical attention.
The pressure in the E.C.S.S. circuit is stored by an accumu-
lator. Do not remove the E.C.S.S. piping or components.
If it is necessary to remove them, please ask your Komatsu
distributor to carry out the removal operation.

PRECAUTIONS FOR HIGH-PRESSURE FUEL 0.

High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection
or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before starting inspection or maintenance.

2-28
SAFETY PRECAUTIONS FOR MAINTENANCE

HANDLING HIGH-PRESSURE HOSES 0.

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury or property damage. 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 all hoses every two years at the latest. The shelf life of the hose should not exceed 2 years.
Replace the hose if any of the following problems are found:
Damaged or leaking hydraulic fitting.
Frayed or cut covering or exposed reinforcement layer of wire.
Covering swollen in places.
Twisted or crushed movable portion.
Foreign material embedded in covering.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.
For details, see "PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (4-13)".

WASTE MATERIALS 0.
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.
Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.

MAINTENANCE OF AIR CONDITIONER 0.

If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frost-
bite. Never touch refrigerant.

COMPRESSED AIR 0.
When carrying out cleaning with compressed air, there is a hazard of serious injury or property damage caused
by flying particles.
When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,
and other protective equipment.

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 0.

In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service
and maintenance at periodic intervals. In order to further increase safety, components with a strong relation-
ship to safety, such as hoses and seat belts, must be replaced at periodic intervals.
Replacement of safety critical parts: See “PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (4-13)“.
The material of these components naturally changes over time, and repeated use causes deterioration, wear,
and fatigue. As a result, there is a hazard that these components may fail and cause serious injury or property
damage. It is difficult to judge the remaining life of these components from external inspection or the feeling
when operating, so always replace them at the specified interval.
Replace or repair safety critical parts if any defect is found, even when they have not reached the time specified
interval.

2-29
PRECAUTIONS WITH TIRES SAFETY

PRECAUTIONS WITH TIRES 0.

HANDLING TIRES 0.
See also “HANDLING THE TIRES (3-109)“.
If tires or rims are handled mistakenly, there is danger that the
tire may explode or be damaged, or that the rim may fly off and
cause serious injury or death.
To maintain safety, always do as follows.
Maintenance, disassembly, repair, and assembly of the tires
and rims requires special equipment and special technol-
ogy, so always ask your Komatsu distributor to carry out
these operations.

Inflate tyres up to the defined pressure. If the tyre pressure

is too low, the tyres may heat up and burst. If the tyre pres-
sure is too high, there is also danger that the tyre may burst.
If a tyre heats up considerably, inflammable gases are pro-
duced. A burning tyre may burst very easily, thus spreading
fire over a large area.
Check the tyre pressure when the tyres are still cold. Do not
let off pressure, when the pressure in a warm tyre has
increased.
Do not light a fire and do not carry out welding near the tyre.
Keep the working area free of pointed or sharp objects that
may damage the tyre.
Avoid any overload.
The values for tyre pressure and permitted speed given in
this manual correspond to the manufacturers' values. See
also "HANDLING THE TIRES (3-109)".
For details, please refer to your Komatsu distributor or the
tyre manufacturer.

PRECAUTIONS WHEN STORING TIRES 0.

Tires for construction equipment are extremely heavy, so they
may cause serious personal injury.
Basically, tyres must be stored in a protected room that can-
not be accessed by unauthorised persons.
Place the tyres on an even surface and incline them 60° to Block
70° against a solid stopper. Secure the tyres with wheel
chocks so that they cannot roll away, tip over, or slip.
If, however, a tyre tips over despite this safety measure, do
not try to stop it, but get out of the way as quickly as possi-
ble, since tyres for construction machines are very heavy
and may cause serious injuries..

2-30
 OPERATION
13

WARNING
Please read and make sure that you understand the safety
volume before reading this section.
GENERAL VIEW OF MACHINE OPERATION

GENERAL VIEW 0.
GENERAL VIEW OF MACHINE 0.

(1) Bucket (8) Turn signal lamp

(2) Tilt lever (9) Head lamp

(3) Front wheel (10) Lift cylinder

(4) Bucket cylinder (11) Lift arm

(5) Front working lamp (12) Rear working lamp

(6) ROPS cab (13) Rear combination lamp

(7) Rear wheel

3-2
OPERATION GENERAL VIEW OF CONTROLS AND GAUGES

GENERAL VIEW OF CONTROLS AND GAUGES 0.

NOTICE
The overview shows a machine with 2-lever control (positions 16 to 21). For machines with multifunction
lever (detail A), see HANDLING MULTIFUNCTION LEVER (6-40).

(1) Gearshift lever stopper (14) Parking brake switch

(2) Rear wiper switch (15) Cigarette lighter

(3) Front wiper switch (16) Load meter cancel switch (option)

(4) Gearshift lever (17) Kickdown switch

(5) Front switch panel (18) Lift arm control lever

(6) Directinal lever (19) Hold switch

(7) E.C.S.S. switch (20) Bucket control lever

(8) Horn switch (21) Load meter subtotal switch (option)

(9) Hazard lamp switch (22) Starting switch

(10) Machine monitor (23) Right switch panel

(11) Steering wheel (24) Accelelator pedal

(12) Transmission cut-off switch (25) Right brake pedal

(13) Lamp switch (26) Steering tilt lock lever

(13) Turn signal lever (27) Left brake pedal

(13) Dimmer switch (28) Safety lock lever

3-3
GENERAL VIEW OF CONTROLS AND GAUGES OPERATION

MACHINE MONITOR

(1) Central warning lamp (20) Joystick pilot lamp (option)

(2) Brake oil pressure caution lamp (21) Directional selector pilot lamp (option)

(3) Engine oil pressure caution lamp (22) Shift indicator

(4) Engine oil level caution lamp (23) Auto-shift pilot lamp

(5) Radiator water level caution lamp (24) Lockup pilot lamp (option)

(6) Air cleaner clogging caution lamp (25) Shift hold pilot lamp

(7) Parking brake pilot lamp (26) Shift lever position pilot lamp

(8) Axle oil temperature caution lamp (27) Torque converter oil temperature gauge

(9) Cooling fan reverse rotation pilot lamp (28) Torque converter oil temperature caution lamp

(10) Maintenance caution lamp (29) Engine water temperature gauge

(11) Battery electrolyte level caution lamp (option) (30) Engine cooling water temperature caution lamp

(12) Battery charge circuit caution lamp (31) Speedometer

(13) Steering oil pressure caution lamp (32) Turn signal pilot lamp

(14) Emergency steering pilot lamp (33) Head lamp high beam pilot lamp

(15) Character display (34) Meter display pilot lamp

(16) Output mode pilot lamp (power mode) (35) Hydraulic oil temperature caution lamp

(17) Preheating pilot lamp (36) Hydraulic temperature gauge

(18) Semi auto digging pilot lamp (option) (37) Fuel level caution lamp

(19) Auto-greasing pilot lamp (38) Fuel gauge

3-4
OPERATION GENERAL VIEW OF CONTROLS AND GAUGES

SWITCH PANEL

RIGHT SWITCH PANEL FRONT SWITCH PANEL

(1) Transmission shift mode selector switch (14) Monitor panel mode selector switch 1

(2) Transmission cut-off set switch (15) Monitor panel mode selector switch 2

(3) Cooling fan reverse rotation switch (16) Front working lamp switch
(4) Emergency steering switch (17) Rear working lamp switch

(5) Semi auto digging switch (option)

(6) Remote positioner raise mode switch (option)

(7) Directional selector actuation switch (option)

(8) Auto-greasing switch

(9) Torque converter lock-up switch (option)

(10) Remote positioner lower mode switch (option)

(11) Remote positioner raise/lower set switch (option)

(12) Starting switch

(13) Power mode selector switch

3-5
MACHINE MONITOR OPERATION

EXPLANATION OF COMPONENTS 0.
The following is an explanation of the devices needed for operating the machine.
To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the
equipment and the meanings of the displays.

MACHINE MONITOR 0.

A: Character display E: Pilot display

B: Emergency stop items F: Meter display

C: CAUTION items G: Central warning lamp

D: Inspection and maintenance items

NOTICE
When turning the starting switch to the ON position before starting the engine, the central warning lamp,
caution lamps, and pilot lamps light up for 2 seconds to check the system.

After the alarm buzzer sounds for 2 seconds, it goes off if the condition is normal.
The shift indicator display shows “88“ for 2 seconds.
The indicator gauges and meters are actuated after the above system check is completed.
The character display shows “KOMATSU SYSTEM CHECK“ for 3 seconds.
If the lamps do not light up, there is probably a failure or disconnection, so contact your Komatsu dis-
tributor for inspection.

3-6
OPERATION MACHINE MONITOR

TYPES OF WARNING 0.
If an abnormality occurs on the machine, or if any switch or
lever is operated mistakenly, the monitor display and buzzer
give a warning to inform the operator.
There are the following types of warning depending on the level
of danger.

REMARK
For details of action codes “E03“ to “E00“, see “ACTION
CODE DISPLAY (3-9)“.

EMERGENCY STOP 0.
This warning is given if there is a serious failure that affects the normal operation of the machine or if the setting is
incorrect.
The central warning lamp on the monitor and the caution lamp for the location of the abnormality light up, and at
the same time, the alarm buzzer sounds and action code “E03“ is displayed on character display (1).

CAUTION 0.
This warning is given if the cooling water or lubricating oil overheat.
The central warning lamp on the monitor and the individual caution lamps light up, and at the same time, the alarm
buzzer sounds and action code “E02“ is displayed on character display (1).

MISTAKEN OPERATION 0.
This warning is given if any switch or lever is operated mistakenly.
The central warning lamp on the monitor lights up, and at the same time, the alarm buzzer sounds and action
code “E00“ is displayed on character display (1).
If there is an individual caution lamp for the mistaken operation, it flashes when the buzzer sounds.

INSPECTION AND MAINTENANCE 0.

This warning is given if it is necessary to carry out inspection and maintenance of wear parts, or if it is necessary to
check the oil or cooling water level.
The individual caution lamp on the monitor lights up, and at the same time, action code “E01“ is displayed on
character display (1).
In the case of this warning, the central warning lamp does not light up and the alarm buzzer does not sound.

CENTRAL WARNING LAMP 0.

This display portion (1) lights up if any emergency stop item,
caution item, or mistaken operation of any switch or lever
occurs. At the same time, the alarm buzzer sounds.
Check the content of the display and carry out the specified
action for the item.

3-7
MACHINE MONITOR OPERATION

CHARACTER DISPLAY PORTION 0.

(1) Service meter (4) Failure code display

(2) Clock (only machines equipped with optional load

(5) Filter, oil replacement time display
meter)

(3) Action code display

Normally, the service meter is displayed on the character display.

If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out
inspection and maintenance, an action code is displayed to recommend suitable action.
When the time for replacing the filter or changing the oil is reached, after completion of the system check with the
starting switch at the ON position, the maintenance monitor caution lamps flash or light up, and at the same time,
the filter or oil to be replaced is displayed.

NOTICE
Information regarding the failure of the machine or maintenance is displayed on the character display
when the starting switch is at the ON position, check the display to confirm that there is no abnormality
before starting to travel.

SERVICE METER 0.
This meter (1) shows the total time that the machine has been
operating.
While the engine is running, the service meter advances even if
the machine is not moving.
The meter advances by 1 for every hour of operation, regard-
less of the engine speed.
Even if the starting switch is at the OFF position, the service
meter will display as long as the top part (‘) of monitor panel
mode selector switch 1 is being pressed.

3-8
OPERATION MACHINE MONITOR

NOTICE
When the starting switch is at the OFF position, if the service meter is displayed even although the top (‘)
of monitor panel mode selector switch 1 is not being pressed, there is probably a failure in the machine,
so please contact your Komatsu distributor for inspection.

CLOCK 0.
(The time display is only available on machines equipped with
the load meter)
This display portion (2) shows the time.
For details of the method of adjusting the time, see “METHOD
OF SETTING TIME ON CLOCK (6-22)“.
Even when the starting switch is at the OFF position, the time
is displayed while the top (‘) position of monitor panel mode
selector switch 1 is being pressed.

ACTION CODE DISPLAY 0.

WARNING
If action code E03 is displayed, stop the machine immediately and check the failure code. For details,
see “FAILURE CODE DISPLAY (3-11)“.
Inform your Komatsu distributor of the failure code and ask for repairs.

If there is a failure on the machine, or it is necessary to change the method of operation, or if inspection or mainte-
nance must be carried out, action code E00, E01, E02, or E03 is displayed on the character display in display por-
tion (3).
If different failures occur at the same time, the action code for the more serious problem is displayed.
The level of seriousness is as follows, starting with the most serious: E03, E02, E01, E00.
In the case of action codes E00, E02, and E03, the alarm buzzer sounds intermittently and the central warning
lamp lights up.

If action codes E00, E01, E02, or E03 are displayed on the character display, stop operations, check the content
of the display, and take the following action.
E03: When this code is displayed, stop the machine immedi-
ately, check the failure code, and contact your Komatsu dis-
tributor for repairs.

REMARK
The top line of the character display displays “E03“ and
the bottom line displays “CHECK RIGHT NOW“ and
“CALL“ in turn for 3 seconds each.
The telephone number is displayed on the right of the
“CALL“ display. If the telephone number has not been
set, there is a blank. For details of the method of set-
ting the telephone number, see “INPUT METHOD FOR
TELEPHONE NUMBER (3-31)“.

3-9
MACHINE MONITOR OPERATION

E02: If overrun related information is displayed, reduce the

engine speed and the speed of the machine while continu-
ing operations.
If the overheat related display is given, stop the machine and
run the engine under no load at a mid-range speed.
If an action code is still displayed after doing this, check the
failure code and contact your Komatsu distributor for
repairs.

REMARK
The top line of the character display displays “E02“ and
the bottom line displays the condition of the machine
related to overrun or overheat.

E01: When a failure occurs in the mechanical system, such as

a drop in the level of the engine cooling water, the mainte-
nance location is displayed and the maintenance caution
lamp lights up. If this happens, carry out inspection and
maintenance of the item indicated after completion of the
day’s work or when changing shifts.
If “MAINTENANCE“ is displayed together with E01, check
the failure code and ask for repairs to be carried out.

REMARK
“E01“ is displayed on the top line of the character display
and “MAINTENANCE or the part of the machine requiring
inspection, filling of fluid, or replacement is displayed on
the bottom line.

E00: If the parking brake has not been properly released or

there is any other mistaken operation, the mistaken opera-
tion is displayed and the machine does not move as oper-
ated by the operator. Return the switches and levers to the
correct position.

REMARK
“E00“ is displayed on the top line of the character display
and the mistaken operation is displayed on the bottom
line.

3-10
OPERATION MACHINE MONITOR

FAILURE CODE DISPLAY 0.

If an action code is displayed on the character display, check the failure code according to the failure code display
method given below.
When contacting your Komatsu distributor to request repairs, please inform your distributor of the failure code.

Method of displaying failure code

1. If an action code is displayed on the character display of
display portion (4), press the top (>) of monitor panel mode
selector switch 2 (1).
The action code will change to the failure code.
The failure code is displayed with the first 6 digits on the
left of the top line of the character display.
The code displayed after the space on the right side of
the failure code indicates the controller that detected the
failure code.
The component causing the failure is displayed on the
bottom line of the character display.

Top right code Controller detecting failure code

MON Machine monitor

TM Transmission controller

ENG Engine controller

WRK Work equipment controller (option)

2. Press the top (>) of monitor panel mode selector switch 2 (1) again.
If the condition is normal, the service meter is displayed for several seconds, then the display returns to the
action code.
If more than one failure has occurred at the same time, the next failure code is displayed.

3-11
MACHINE MONITOR OPERATION

FILTER, OIL REPLACEMENT TIME DISPLAY 0.

After completion of the system check when the starting switch
is turned ON, if any filter or oil item is approaching the replace-
ment time, this display (5) shows the item for approx. 30 sec-
onds. When this happens, the maintenance caution lamp also
flashes or lights up.
After replacing the filter or changing the oil, reset the time for
replacement. For details, see “ (3-30)“.

REMARK
The top line of the character display shows the ID No. and item name for the item needing replacement;
the bottom line shows the time remaining until replacement and the total number of times the replace-
ment has been carried out.
If the replacement time has already passed, a minus (-) sign appears before the time.
After the display has been given for 30 seconds, it does not appear again until the starting switch is
turned to the ON position.
The message in the illustration above is not shown on the character display if an action code is being
displayed.
If there are two or more items to be displayed, the display changes repeatedly every three seconds. If
there are more than 10 items, all the items are displayed once each, then the display returns to the nor-
mal display.
The display appears when there is 30 hours remaining until the filter or oil replacement time. If the
replacement time has passed, a minus (-) sign appears before the time for the first 30 hours. When
more than 30 hours have passed, the display is no longer given.
The maintenance caution lamp flashes as the replacement time approaches, and after the replacement
time has passed, it lights up.

Items for display of filter, oil replacement time

Replacement
Item Character display ID number
interval (H)

Engine oil 500 ENG OIL 01

Engine oil filter 500 ENG FILT 02

Fuel filter 500 FUEL FILT 03

Corrosion resistor 1000 CORR RES 06

Transmission oil 1000 TM OIL 12

Transmission oil filter 1000 TM FILT 13

Hydraulic filter 2000 HYD FILT 04

Hydraulic tank breather element 2000 HYD BREATH 05

Hydraulic oil 2000 HYD OIL 10

Axle oil 2000 AXLE OIL 15

3-12
OPERATION MACHINE MONITOR

REMARK
See the section below for details of the procedure for replacing the filter and oil.
Engine oil
“CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (4-44)“
Engine oil filter
“CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (4-44)“
Fuel filter
“REPLACE FUEL FILTER CARTRIDGE (4-45)“
Corrosion resistor
“REPLACE CORROSION RESISTOR CARTRIDGE (4-47)“
Transmission oil
“CHANGE TRANSMISSION OIL AND FILTER, CLEAN STRAINER (4-46)“
Transmission oil filter
“CHANGE TRANSMISSION OIL AND FILTER, CLEAN STRAINER (4-46)“
Hydraulic filter
“CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT (4-48)“
Hydraulic tank breather element
“REPLACE HYDRAULIC TANK BREATHER ELEMENT (4-50)“
Hydraulic oil
“CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT (4-48)“
Axle oil
“CHANGE AXLE OIL (4-51)“

3-13
MACHINE MONITOR OPERATION

EMERGENCY STOP ITEM 0.

CAUTION
If these monitors light up and the buzzer sounds, stop operations immediately and carry out inspection
and maintenance of the applicable location.

If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the monitor
for the location of the abnormality and the central warning lamp will light up.
At the same time, “E03 CHECK RIGHT NOW“ is displayed on the character display, so stop the machine immedi-
ately in a safe place, stop the engine, and carry out inspection.

(1) Brake oil pressure caution lamp (3) Battery charge circuit caution lamp

(2) Engine oil pressure caution lamp (4) Steering oil pressure caution lamp

BRAKE OIL PRESSURE CAUTION LAMP 0.

This monitor (1) lights up when the brake oil pressure goes
below the specified value.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), the
brake circuit is not actuated while the engine is stopped, so the
brake oil pressure caution lamp and central warning lamp do
not light up and the alarm buzzer does not sound.

3-14
OPERATION MACHINE MONITOR

During operation (engine running)

If the brake oil pressure goes down during operation, the brake oil pressure caution lamp and central warning
lamp light up and the alarm buzzer sounds intermittently.
At the same time, “E03 CHECK RIGHT NOW“ is displayed on the character display, so stop the machine immedi-
ately in a safe place, stop the engine, and carry out inspection.
If the brake oil pressure caution lamp lights up, the footbrake may not work, so keep the parking brake applied to
prevent the machine from moving.
In addition, when the accumulator is being charged immediately after starting the engine, the brake oil pressure
caution lamp will light up, but the central warning lamp remains OFF and the alarm buzzer does not sound.
Keep the parking brake applied to prevent the machine from moving until the brake pressure becomes normal and
the brake oil pressure caution lamp goes out.

ENGINE OIL PRESSURE CAUTION LAMP 0.

This monitor (2) lights up to warn the operator that the engine
lubricating oil pressure has dropped.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), this
monitor does not light up.

During operation (engine running)

If the engine lubricating oil pressure goes down during opera-
tion, the engine lubricating oil pressure caution lamp and cen-
tral warning lamp light up and the alarm buzzer sounds
intermittently.
At the same time, “E03 CHECK RIGHT NOW“ is displayed on the character display, so stop the machine immedi-
ately in a safe place, stop the engine, and carry out inspection.

BATTERY CHARGE CIRCUIT CAUTION LAMP 0.

This monitor (3) lights up when the engine is running to warn
the operator that an abnormality has occurrred in the charging
circuit.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), this
monitor does not light up.

During operation (engine running)

If an abnormality occurrs in the charging circuit during opera-
tion, the battery charge circuit caution lamp and central warn-
ing lamp light up and the alarm buzzer sounds intermittently.
At the same time, “E03 CHECK RIGHT NOW“ is displayed on the character display, so stop the machine immedi-
ately in a safe place, stop the engine, and carry out inspection.

STEERING OIL PRESSURE CAUTION LAMP 0.

(Red)
This monitor (4) lights up to warn the operator that the steering
oil pressure has dropped.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), this
monitor does not light up.
However, it lights up during the self-check of the emergency
steering.

During operation (engine running)

If the steering oil pressure goes down during operation, the
steering oil pressure caution lamp and central warning lamp
light up and the alarm buzzer sounds intermittently.
At the same time, “E03 CHECK RIGHT NOW“ is displayed on the character display, so stop the machine immedi-
ately in a safe place, stop the engine, and carry out inspection.

3-15
MACHINE MONITOR OPERATION

CAUTION ITEMS 0.

CAUTION
If these monitors light up, stop operations quickly and carry out the following action.

(1) Axle oil temperature caution lamp (4) Hydraulic oil temperature caution lamp

(2) Torque converter oil temperature caution lamp (5) Fuel level caution lamp
(3) Engine cooling water temperature caution lamp

AXLE OIL TEMPERATURE CAUTION LAMP 0.

This monitor (1) lights up to warn the operator that the brake
oil temperature has risen.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), this
monitor does not light up.

During operation (engine running)

In continuous heavy-duty operations or when traveling long dis-
tances downhill where of the brake is used frequently, the axle
oil temperature becomes high so the axle oil temperature cau-
tion lamp lights up and the alarm buzzer sounds intermittently.
At the same time, “E02 BRAKE OVERHEAT“ is displayed on
the character display, so take the following action.
1. Release the accelerator pedal and move the gearshift lever down one range to reduce the travel speed.
2. Avoid using the brake.
1) Do not keep the brake pedal depressed continuously; use the brake only intermittently.
2) When using the left brake pedal, turn the transmission cut-off switch ON to carry out operations.

3-16
OPERATION MACHINE MONITOR

If use of the brake is reduced for a short time in the way recommended above, the axle oil temperature will
go down and the caution lamp will go out.

TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP 0.

This monitor (2) lights up to warn the operator that the torque
converter oil temperature has risen.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), this
monitor does not light up.
During operation (engine running)
If the torque converter oil temperature rises, the torque con-
verter oil temperature caution lamp only will light up.
If the oil temperature rises further, the central warning lamp will
light up and the alarm buzzer will sound intermittently.
At the same time as the central warning lamp lights up, “E02
TC OVERHEAT“ is displayed on the character display, so stop
the machine and run the engine under no load at a mid-range
speed until the lamp goes out.

ENGINE COOLING WATER TEMPERATURE CAUTION LAMP 0.

This monitor (3) lights up to warn the operator that the engine
cooling water temperature has risen.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), this
monitor does not light up.
During operation (engine running)
If the engine cooling water temperature rises, the engine cool-
ing water temperature caution lamp only will light up.
If the water temperature rises further, the central warning lamp
will light up and the alarm buzzer will sound intermittently.
At the same time as the central warning lamp lights up, “E02
ENGINE OVERHEAT“ is displayed on the character display, so
stop the machine and run the engine under no load at a mid-
range speed until the lamp goes out.

HYDRAULIC OIL TEMPERATURE CAUTION LAMP 0.

This monitor (4) lights up to warn the operator that the hydrau-
lic oil temperature has risen.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), this
monitor does not light up.
During operation (engine running)
If the hydraulic oil temperature rises, the hydraulic oil tempera-
ture caution lamp, the central warning lamp will light up, and
the alarm buzzer will sound intermittently.
At the same time, “E02 HYD OVERHEAT“ is displayed on the
character display, so stop the machine and run the engine
under no load at a mid-range speed until the lamp goes out.

3-17
MACHINE MONITOR OPERATION

FUEL LEVEL CAUTION LAMP 0.

This monitor (5) lights up if the amount of fuel remaining in the
fuel tank goes below 27 liters.
If it lights up, check and add fuel and as soon as possible.

REMARK
Even if the caution lamp lights up, action code “E02“ is not dis-
played on the character display.

3-18
OPERATION MACHINE MONITOR

INSPECTION AND MAINTENANCE ITEM 0.

CAUTION
If these monitors light up, stop operations quickly and carry out the following action.

(1) Engine oil level caution lamp (5) Battery electrolyte level caution lamp (option)

(2) Radiator water level caution lamp (6) Breake oil level caution lamp

(3) Air cleaner clogging caution lamp (7) Transmission oil filter clogging caution lamp

(4) Maintenance caution lamp

ENGINE OIL LEVEL CAUTION LAMP 0.

This monitor (1) lights up to warn the operator that the oil level
in the engine oil pan has gone down.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), this
monitor lights up if the oil level in the engine oil pan is low.

At the same time, “E01 ENG OIL LEV LOW“ is displayed on the
character display, so do not start the engine. Check the oil
level in the engine oil pan and add oil.

3-19
MACHINE MONITOR OPERATION

REMARK
During checks before starting, if the engine is started with the engine oil level caution lamp lighted up, the
lamp will stay lighted up.

During operation (engine running)

If the oil level in the engine oil pan becomes too low, the engine oil level caution lamp will light up.
At the same time, “E01 ENG OIL LEV LOW“ is displayed on the character display, so stop the engine, check the oil
level in the engine oil pan, and add oil.

RADIATOR WATER LEVEL CAUTION LAMP 0.

This monitor (2) lights up to warn the operator that the water
level in the radiator has gone down.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), this
monitor lights up if the water level in the radiator is low.

At the same time, “E01 COOLANT LOW“ is displayed on the

character display, so check the water level in the radiator and
add water.

During operation (engine running)

If the water level in the radiator becomes too low, the radiator
cooling water level caution lamp will light up.
At the same time, “E01 COOLANT LOW“ is displayed on the
character display, so stop the engine, check the water level in
the radiator, and add water.

AIR CLEANER CLOGGING CAUTION LAMP 0.

This lamp (3) lights up to warn the operator that the air cleaner
is clogged.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), this
monitor does not light up.

During operation (engine running)

If the air cleaner becomes clogged, the air cleaner clogging
caution lamp will light up.
At the same time, “E01 AIR FILTER“ is displayed on the char-
acter display, so stop the engine and clean or replace the ele-
ment.

REMARK
It is possible to check the condition of clogging of the air cleaner with the dust indicator installed at the
side of the air cleaner.

3-20
OPERATION MACHINE MONITOR

MAINTENANCE CAUTION LAMP 0.

CAUTION
If the caution monitor lamp lights up, repair the problem as soon as possible.

When the time for oil change is reached, this monitor (4)
flashes or lights up for approx. 30 seconds after completion of
the system check when the starting switch is at the ON posi-
tion.

REMARK
The maintenance caution lamp flashes when there is less
than 30 hours to the replacement time, and after the
replacement time has passed, it lights up.

For details of the items covered by filter and oil replacement,

see “FILTER, OIL REPLACEMENT TIME DISPLAY (3-12)“.
After replacing the filter or changing the oil, reset time for the replacement. For details, see “ (3-30)“.

BATTERY ELECTROLYTE LEVEL CAUTION LAMP 0.

(option)
This monitor (5) lights up to warn the operator that the battery
electrolyte level has gone down.
During checks before starting (when the starting switch is
turned to the ON position but the engine is not started), this
monitor lights up if the battery electrolyte level is low.
At the same time, “E01 BATTERY LEV LOW“ is displayed on
the character display, so check the electrolyte level and add
distilled water.

During operation (engine running)

If the battery electrolyte level becomes too low, the battery
electrolyte level caution lamp will light up.
At the same time, “E01 BATTERY LEV LOW“ is displayed on
the character display, so check the electrolyte level and add
distilled water.

BRAKE OIL LEVEL CAUTION LAMP 0.

This monitor (6) is not used.
On this machine, the hydraulic oil is used for the brake oil.

3-21
MACHINE MONITOR OPERATION

TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP 0.

This monitor (7) is not used.

3-22
OPERATION MACHINE MONITOR

PILOT DISPLAY PORTION 0.

When the starting switch is ON, the pilot display lights up when the display items are functioning.

(1) Parking brake pilot lamp (9) Directional selector pilot lamp (option)

(2) Cooling fan reverse rotation pilot lamp (10) Shift indicator

(3) Emergency steering pilot lamp (11) Auto-shift pilot lamp

(4) Output mode pilot lamp (power mode) (12) Lockup pilot lamp (option)

(5) Preheating pilot lamp (13) Shift hold pilot lamp

(6) Semi auto digging pilot lamp (option) (14) Shift lever position pilot lamp

(7) Auto-greasing pilot lamp (15) Turn signal pilot lamp

(8) Joystick pilot lamp (option) (16) Head lamp high beam pilot lamp

3-23
MACHINE MONITOR OPERATION

PARKING BRAKE PILOT LAMP 0.

This monitor (1) lights up when the parking brake is applied.

COOLING FAN REVERSE ROTATION PILOT LAMP 0.

This monitor (2) lights up when the direction of rotation of the
cooling fan is reversed.
At the same time, “COOLING FAN REVERSE“ is displayed on
the character display.

REMARK
When the engine is running, even if the cooling fan reverse
switch is operated, the fan does not rotate in reverse.
In this case, the position of the switch and the actual direc-
tion of rotation of the fan are different, so the cooling fan
reverse rotation pilot lamp flashes.
Return the switch to its original position or stop the engine
and operate the switch.

EMERGENCY STEERING PILOT LAMP 0.

(Green)

This monitor (3) lights up when the emergency steering is

being actuated.
If the engine stops when the machine is traveling or an abnor-
mality occurs in the steering oil pressure circuit, and the
machine is traveling at a speed of more than 2 km/h, the emer-
gency steering is automatically actuated and the lamp lights
up.
If the lamp lights up, move the machine immediately to a safe
place, stop the engine, and check the condition.
In addition, the lamp flashes if the emergency steering is actuated continuously for one minute.
At the same time, “E02 EMR S/T OVERRUN“ is displayed on the character display, so move the machine imme-
diately to a safe place, stop the engine, and check the condition.

There is an emergency steering self-check function. For details, see “EMERGENCY STEERING SELF-CHECK
FUNCTION (3-94)“ in the OPERATION section.

3-24
OPERATION MACHINE MONITOR

OUTPUT MODE PILOT LAMP (POWER MODE) 0.

This monitor (4) lights up when the power mode is selected.
Use the power mode selector switch to select the output mode.

PREHEATING PILOT LAMP 0.

This monitor (5) lights up when the engine preheating electric
heater is actuated.
In cold weather, when the starting switch is turned to the ON
position, this lamp lights up, and when the preheating is com-
pleted, it goes out.
The preheating time differs according to the ambient tempera-
ture.

SEMI AUTO DIGGING PILOT LAMP 0.

(option)
For details, see “EPC WORK EQUIPMENT LEVER (6-55)“ in the ATTACHMENT AND OPTIONS section.

AUTO-GREASING PILOT LAMP 0.

For details, see “CENTRAL LUBRICATION (6-37)“ in the ATTACHMENT AND OPTIONS section.

JOYSTICK PILOT LAMP 0.

(option)
For details, see “JOYSTICK STEERING SYSTEM (6-47)“.

DIRECTIONAL SELECTOR PILOT LAMP 0.

(option)
This monitor (9) lights up when the directional selector switch
actuation switch on the right switch panel is turned ON to make
it possible to switch the direction of travel between FORWARD
and REVERSE with the directional selector switch at the side
of the lift arm control lever.
For details, see “CHANGING DIRECTION (3-88)“.

3-25
MACHINE MONITOR OPERATION

SHIFT INDICATOR 0.
This monitor (10) indicates the transmission gear range (actual
travel speed range).

AUTO-SHIFT PILOT LAMP 0.

This monitor (11) lights up when the auto-shift function is
selected.
Use the transmission shift mode selector switch to select the
shift mode.

LOCKUP PILOT LAMP 0.

(option)
For details, see “HANDLING TORQUE CONVERTER LOCK-UP (6-27)“ in the ATTACHMENT AND OPTION sec-
tion.

SHIFT HOLD PILOT LAMP 0.

This monitor (13) lights up when the shift hold is actuated.

SHIFT LEVER POSITION PILOT LAMP 0.

This monitor (14) displays the transmission position of the
gearshift lever.

3-26
OPERATION MACHINE MONITOR

TURN SIGNAL PILOT LAMP 0.

This monitor (15) flashes at the same time as the turn signal
lamp flashes.

If there is a disconnection in the turn signal indicator lamp, the

flashing interval becomes shorter.

HEAD LAMP HIGH BEAM PILOT LAMP 0.

This monitor (16) lights up when the head lamps are set to high
beam.

3-27
MACHINE MONITOR OPERATION

METER DISPLAY PORTION 0.

(1) Torque converter oil temperature gauge (4) Fuel gauge

(2) Engine water temperature gauge (5) Speedometer

(3) Hydraulic temperature gauge (6) Meter display pilot lamp

TORQUE CONVERTER OIL TEMPERATURE GAUGE 0.

This meter (1) indicates the torque converter oil temperature.
It should be in the white range during operation.
If it is in the red range during operation, the alarm buzzer will
sound and the central warning lamp will light up. “E02 TC
OVERHEAT“ is displayed on the character display, so run the
engine under no load at a mid-range speed and wait until the
meter enters the white range.

ENGINE WATER TEMPERATURE GAUGE 0.

This meter (2) indicates the engine water temperature.
It should be in the white range during operation.
If it is in the red range during operation, the alarm buzzer will
sound and the central warning lamp will light up. “E02 ENGINE
OVERHEAT“ is displayed on the character display, so run at
the engine under no load at a mid-range speed and wait until
the meter enters the white range.
If it is in the red range, the engine output is automatically lim-
ited.

3-28
OPERATION MACHINE MONITOR

HYDRAULIC TEMPERATURE GAUGE 0.

This meter (3) indicates the hydraulic oil temperature.
During normal operations, it should be in the white range.
If it enters the red range during operation, the alarm buzzer will
sound and the central warning lamp will light up at the same
time. “E02 HYD OVERHEAT“ is displayed on the character
display, so run the engine under no load at a mid-range speed
and wait until the indicator returns to the white range.

FUEL GAUGE 0.
This meter (4) indicates the amount of fuel remaining in the fuel
tank.
F: Full tank
E: Fuel level is low
When the amount of remaining fuel goes below 27 liters, the
caution lamp inside the fuel gauge lights up.
If it lights up, check and add fuel.

SPEEDOMETER 0.
This meter (5) indicates the travel speed of the machine.
The display unit is indicated on meter display pilot lamp (6).
It is also possible to display the engine speed by switching
meter (5).
If you wish to switch between the speedometer and tachome-
ter, please contact your Komatsu distributor to have it
switched.

METER DISPLAY PILOT LAMP 0.

This lamp (6) displays the unit for the travel speed or engine
tachometer.

3-29
MACHINE MONITOR OPERATION

OTHER FUNCTIONS OF MACHINE MONITOR 0.

The machine monitor also has the following functions.
Odometer, filter/oil replacement time reset, telephone number input, language selection, monitor brightness
adjustment

METHOD OF DISPLAYING ODOMETER 0.

Use this when checking the total distance that the machine has traveled.
1. Check that the character display is showing the service meter or the action code. If it is giving any other dis-
play, turn the starting switch OFF, then turn the starting switch to the ON position and wait for the above display
to be given.
2. Press the (‘) of monitor panel mode selector switch 1. It
displays the odometer.
3. When completing the operation, press („) of monitor panel
mode selector switch 1 or turn the starting switch OFF.

0.

0.

RESET METHOD FOR FILTER, OIL REPLACEMENT

TIME 0.
The filter and oil replacement time is displayed on the character
display, so if the filter and oil have been replaced, reset the fil-
ter and oil change time.
1. Press the (‘) of monitor panel mode selector switch 1, and display the odometer.
2. Press (>) or (<) of monitor panel mode selector switch 2 and
display “MAINTENANCE MONITOR“.

3. Press the (‘) of monitor panel mode selector switch 1. It

will change to the display in the diagram on the right.
The bottom line shows two items: the replacement time on
the left and the total number of times the item has been
replaced on the right.
4. Press the (>) or (<) of monitor panel mode selector switch 2
to display
the item (filter or oil) which has reached the replacement
time.

3-30
OPERATION MACHINE MONITOR

5. Press the (‘) of monitor panel mode selector switch 1. It

will change to the display in the diagram on the right.
The top line shows [Reset] and [Item to be reset] in turn.
6. When resetting the replacement time, press (>) or (<) of
monitor panel mode selector switch 2, align the cursor with
“YES“, then press („) of machine monitor mode selector
switch 1. It will reset and returned to the previous screen.
To abandon, align the cursor with “NO“, then press („) of
monitor panel mode selector switch 1.
7. When resetting the replacement time for another item, carry
out the procedure from Step 4. After completing, press („)
of monitor panel mode selector switch 1 twice or turn the
starting switch OFF.

INPUT METHOD FOR TELEPHONE NUMBER 0.

It is possible to display the telephone number on the right side of “CALL“ displayed on the character display when
action code “E03“ is generated.

1. Press the (‘) of monitor panel mode selector switch 1, and display the odometer.
2. Press (>) or (<) of monitor panel mode selector switch 2 and
display “TEL“.

3. Press (‘) of monitor panel mode selector switch 1. It will

change to the display in the diagram on the right.

Once the telephone number is input, the input number will

be displayed next time.

4. Up to 12 digits can be displayed for the telephone number.

Input from the first digits.
The cursor is displayed at the input position. Press (>) or
(<) of monitor panel mode selector switch 2 and display “0 -
9 “. To leave a blank, select “*“.
When the input value is decided, press (‘) of monitor panel
mode selector switch 1. The cursor will move to the next
position.
5. Repeat the procedure in Step 4 until the last digit. At the last digit, press (‘) of monitor panel mode selector
switch 1 to return to the previous screen.
If there is a mistake in the input or the input is to be stopped, press („) of monitor panel mode selector switch 1
to return to the previous screen.
6. When completing the operation, press („) of monitor panel mode selector switch 2 twice or turn the starting
switch OFF.

3-31
MACHINE MONITOR OPERATION

METHOD FOR SELECTING LANGUAGE 0.

Use this when switching the language displayed on the character display.
The following explanation is for when english is set as the language for the character display.

1. Press the (‘) of monitor panel mode selector switch 1, and display the odometer.
2. Press (>) or (<) of monitor panel mode selector switch 2 and
display “LGUAGE“.

3. Press the (‘) of machine mode panel selector switch 1.

The presently selected language is displayed.
4. Press (>) or (<) of monitor panel mode selector switch 2 and
select the language.
The available languages are English, Japanese,
German, French, Italian, Spanish, and Swedish.

5. After selecting the language, press the (‘) of monitor panel

mode selector switch 1.
To confirm, set the cursor at “YES“, then press the („) of
monitor panel mode selector switch 1. The language will be
selected and the screen will return to the previous screen.
To abort, set the cursor at “NO“, then press the („) of moni-
tor panel mode selector switch 1.
6. When completing the operation, press („) of monitor panel
mode selector switch 2 twice or turn the starting switch OFF.

3-32
OPERATION MACHINE MONITOR

METHOD OF ADJUSTING MONITOR BRIGHTNESS 0.

Do as follows to adjust the brightness of the monitor.

1. Press the (‘) of monitor panel mode selector switch 1, and display the odometer.
2. Press (>) or (<) of monitor panel mode selector switch 2 and
display “BRIGHTNESS ADJUST“.

3. Press the (‘) of monitor panel mode selector switch 1.

“MONITOR PANEL“ will be displayed on the bottom line
and it will be possible to adjust the brightness of the monitor.

The brightness can be adjusted for the overall monitor or for

the liquid crystal display only.
To adjust only the brightness of the liquid crystal display, press
the (>) or (<) of monitor panel mode selector switch 2 to
switch the display to “LCD PANEL“.

4. Press the (‘) of monitor panel mode selector switch 1. The

screen will change to the display shown on the right and it
will be possible to adjust the brightness.
5. Press the (>) or (<) of monitor panel mode selector switch 2
to select a level between L and H (available range: 7
stages).
6. After selecting the brightness, press the („) of monitor
panel mode selector switch 1.
The brightness will be selected and the screen will return to
the previous screen.
7. When completing the operation, press („) of monitor panel
mode selector switch 2 twice or turn the starting switch OFF.

3-33
SWITCHES OPERATION

SWITCHES 0.
NOTICE
The overview shows a machine with 2-lever control (positions 14, 15, 24, 32 and 33). For machines with
multifunction lever (detail A), see HANDLING MULTIFUNCTION LEVER (6-40).

(1) Starting switch (17) Rear wiper switch

(2) Power mode selector switch (18) Cigarette lighter
(3) Transmission shift mode selector switch (19) Room lamp switch
(4) Transmission cut-off switch (20) Rear heated wire glass switch
(5) Transmission cut-off set switch (21) E.C.S.S. switch
(6) Lamp switch (22) Emergency steering switch
(6) Turn signal lever (23) Cooling fan reverse rotation switch
(6) Dimmer switch (24) Directional selector switch (option)
(7) Horn button (25) Directional selector actuation switch (option)
(8) Hazard lamp switch (26) Semi auto digging switch (option)
(9) Parking brake switch (27) Remote positioner raise mode switch (option)
(10) Front working lamp switch (28) Remote positioner lower mode switch (option)
(11) Rear working lamp switch (29) Remote positioner raise/lower set switch (option)
(12) Monitor panel mode selector switch 1 (30) Aftercooler tilt switch
(13) Monitor panel mode selector switch 2 (31) Torque converter lock-up switch (option)
(14) Kickdown switch (32) Load meter cancel switch (option)
(15) Hold switch (33) Load meter subtotal switch (option)
(16) Front wiper switch

3-34
OPERATION SWITCHES

STARTING SWITCH 0.
This switch(1) is used to start or stop the engine.

OFF position
It is possible to insert and remove the starting switch key, all
the electric system switches are turned off, and the engine
stops. In addition, the parking brake is automatically applied.

ON position
Electric current flows in the charging circuit, lamp circuit, and
accessory circuit.
Keep the starting switch key at the ON position while the
engine is running.

START position
This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately
after the engine has been started. The key will return to the ON position when released.

POWER MODE SELECTOR SWITCH 0.

This switch (2) can be used to switch the engine output to
match the purpose of the operation.
When the POWER mode is selected, the output mode pilot
lamp (POWER mode) on the machine monitor lights up.

NORMAL position: Normal mode (low engine output), opera-

tions where emphasis is on fuel consumption, such as
operations on flat ground where high engine output is not
needed.
POWER position: Power mode (high engine output), opera-
tions where emphasis is on production.
REMARK
To carry out operations with effective fuel consumption, normally set to the NORMAL mode.
The maximum engine speed is set lower than in the POWER mode, but except for hard operations such
as heavy-duty digging of rock, it can display ample power and can also display good fuel consumption.
Furthermore, by pressing the accelerator pedal lightly, it is possible to reduce the fuel consumption.
Set to the POWER mode when carrying out heavy-duty digging operations of rock or operations where
the speed is required, or when traveling at high speed on flat ground or on slopes.

3-35
SWITCHES OPERATION

TRANSMISSION SHIFT MODE SELECTOR SWITCH 0.

This switch (3) is used to change the shift point when the
AUTO SHIFT/MANUAL selector switch has been switched to
auto shift.
At each of the L, M, and H positions, the system switches to
auto shift and the auto shift pilot lamp on the machine monitor
lights up. Normally, set to auto shift.

MANUAL position: System is set to manual shift and speed

range is a position selected by gearshift lever
L position: Travel speed when shifting up is low (flat ground,
normal travel)
M position: Travel speed when shifting up is medium (traveling
uphill, traveling at high speed)
H position: Travel speed when shifting up is high (traveling
uphill, traveling at high speed)
REMARK
For details of the manual shift, see “MANUAL SHIFT (3-47)“.
For details of the auto-shift, see “AUTOMATIC SHIFT (3-48)“.

TRANSMISSION CUT-OFF SWITCH 0.

WARNING
When moving the machine off on an uphill slope, set the transmission cut-off switch to the OFF position,
depress the accelerator pedal while keeping the left brake pedal depressed, then gradually release the
brake pedal and allow the machine to move. In this way the machine can be prevented from traveling
backwards.

Press this switch (4) to turn on and off the transmission cut-off
system.
When the switch is pressed, the pilot lamp lights up and the
system is turned ON. The transmission is shifted to neutral at
the adjusted brake pedal depression position.
Normally, keep the switch at the ON position.

For details of the method of adjusting the cut-off position, see

“ADJUSTING TRANSMISSION CUT-OFF (3-92)“ in the STOP-
PING MACHINE section.

Position (a): OFF

The left brake pedal acts in the same way as the normal brake (right brake pedal).
Position (b): ON
The left brake pedal acts in the same way as the normal brake, and at the same time, sets the transmission to
neutral.

REMARK
The brake pedal position where the cut-off system is actuated can be adjusted by using the transmission
cut-off set switch on the right switch panel.

TRANSMISSION CUT-OFF SET SWITCH 0.

CAUTION
Apply the parking brake before adjusting the transmission cut-off position.

3-36
OPERATION SWITCHES

Turn this switch (5) ON to adjust the brake pedal position

where the transmission is automatically shifted to Neutral.
Position (a): ON
Cut-off position can be adjusted

When the switch is released, it automatically returns to its origi-

nal position.

For details of the method of adjusting the cut-off position, see

“ADJUSTING TRANSMISSION CUT-OFF (3-92)“ in the STOP-
PING MACHINE section.

LAMP SWITCH 0.
This switch (6) is used to light up the front lamps, side clear-
ance 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 posi-
tion of the lever.

TURN SIGNAL LEVER 0.

This switch (6) is used to operate the turn signal lamp.
(a) position : LEFT TURN (Push lever FORWARD.)
(b) position : RIGHT TURN (Pull lever BACK.)

REMARK
When the lever is operated, the pilot lamp turn signal
pilot lamp also flashes.
When the steering wheel is turned back, the lever auto-
matically returns to its original position. If it does not OFF
return, return it by hand.

DIMMER SWITCH 0.
This switch (6) is used to switch the head lamps between high
beam and low beam.
Position (a): Low beam
Position (b): High beam

3-37
SWITCHES OPERATION

HORN BUTTON 0.
When the horn button (7) in the center of the steering wheel is
pressed, the horn will sound.

HAZARD LAMP SWITCH 0.

WARNING
ON
Use the hazard lamp only in emergencies. Using the haz- OFF
ard lamp when traveling will cause problems for other
machines.

This switch (8) is used in emergencies, such as when the

machine breaks down and has to be parked on the road.
ON position: All turn signal lamps flash.

REMARK
When this switch is turned to the ON position, the turn direction indicator lamps and turn indicator pilot
lamp flash, and display lamp (A) lights up at the same time.

3-38
OPERATION SWITCHES

PARKING BRAKE SWITCH 0.

WARNING
Always apply the parking brake when leaving the machine
or when parking it.
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.

This switch (9) operates the parking brake.

Position (a): ON
The parking brake is applied, and the parking brake pilot
lamp lights up.
Position (b): OFF
The parking brake is released.

NOTICE
Never use the parking brake switch to apply the brakes when traveling, except in an emergency. The
parking brake may be damaged and this may lead to a serious accident. Apply the parking brake only
after the machine has stopped.
If the parking brake has been used as an emergency brake when traveling at high speed, contact your
Komatsu distributor to have the parking brake checked for any abnormality.

REMARK
When the parking brake is applied, the machine will not move off even if the directional lever is oper-
ated.
If the directional lever is placed at the F or R position with the parking brake still applied, the central
warning lamp will light up and the buzzer will sound. At the same time, “E00 PARKING BRAKE“ will be
displayed on the character display.
Before starting the engine, turn the parking brake switch ON, then turn it OFF again.

FRONT WORKING LAMP SWITCH 0.

WARNING
Always turn the working lamp off before traveling on pub-
lic roads.

When turning the front working lamp ON, operate the lamp
switch to turn the side clearance lamp ON or the head lamp
ON, then operate this switch (10).
Position (a): Working lamp lights up
Position (b): Working lamp goes out
If position (a) is pressed, the pilot lamp will light up and the working lamp circuit will be switched ON.
If the lamp switch is not at the ON position for the side clearance lamp or head lamp, the working lamp will not light
up.

3-39
SWITCHES OPERATION

REAR WORKING LAMP SWITCH 0.

WARNING
Always turn the working lamp off before traveling on pub-
lic roads.

When turning the rear working lamp ON, operate the lamp
switch to turn the side clearance lamp ON or the head lamp
ON, then operate this switch (11).
Position (a): Working lamp lights up
Position (b): Working lamp goes out
If position (a) is pressed, the pilot lamp will light up and the working lamp circuit will be switched ON.
If the lamp switch is not at the ON position for the side clearance lamp or head lamp, the working lamp will not light
up.

MONITOR PANEL MODE SELECTOR SWITCH 1 0.

This switch (12) is used to switch the function of the character
display.
When the switch is released, it automatically returns to its origi-
nal position.

The basic operation is as follows.

Position (‘):
Press here to select (confirm) each mode or operation
Position („):
Press here to cancel each mode or operation

3-40
OPERATION SWITCHES

MONITOR PANEL MODE SELECTOR SWITCH 2 0.

This switch (13) is used to switch the function of the character
display.
When the switch is released, it automatically returns to its origi-
nal position.

The basic operation is as follows.

Position (>): Press here to go on to the next screen, or to move
the cursor forward, or to increase the number when input-
ting numerals
Position (<): Press here to go back to the previous screen, or to
move the cursor back, or to reduce the number when input-
ting numerals

KICKDOWN SWITCH 0.
NOTICE
The following describes a machine with 2-lever control. For machines with multifunction lever,
see HANDLING MULTIFUNCTION LEVER (6-40).

When the gearshift lever is in 2nd, if switch (14) on the head of

the lift arm control lever is pressed, the transmission will shift
down to 1st.
Use this when you need to increase the drawbar pull in digging
operations.

If the transmission is in auto-shift, and the travel speed is below

12.5 km/h in any speed range when traveling in either forward
or in reverse, the kick-down switch is actuated and it is possible
to shift down to 1st.

This makes it easy to carry out load and carry operations.

Even if the travel speed is more than 12.5 km/h, this switch can be used to shift the transmission down. Each time
the kick-down switch is pressed, the speed range will shift down one range at a time (F4 -> F3 -> F2).
When the torque converter is in the lock-up condition (option), the lock-up is canceled.

REMARK
When canceling the kick-down, operate the directional lever. In manual shift, the kick-down can be
canceled by operating the gearshift lever to any position other than 2nd. It is also possible to cancel
the kick-down by turning the starting switch OFF.
In auto-shift, if the travel speed becomes high after the kick-down, the gear will be shifted up by the
auto-shift.
In auto-shift, when traveling at more than 25 km/h in 3rd or at more than 35 km/h in 4th, even if the kick-
down switch is pressed, the transmission will not shift down. This is to prevent overrun of the engine.

3-41
SWITCHES OPERATION

HOLD SWITCH 0.
NOTICE
The following describes a machine with 2-lever control. For machines with multifunction lever,
see HANDLING MULTIFUNCTION LEVER (6-40).

To fix the speed range when traveling in automatic transmis-

sion, press switch (15) at the side of the lift arm control lever
knob. The transmission will be fixed in the speed range dis-
played on shift indicator (A) on the machine monitor and shift
hold pilot lamp (B) will light up.
When the switch is pressed again, the display goes out.
Use this function to select the desired speed range when trav-
eling up or down hills or when carrying out operations such as
grading.

REMARK
When the torque converter is in the lock-up condition
(option), the transmission cannot be fixed.
When canceling the shift hold, operate the directional
lever or gearshift lever or operate the transmission shift
mode selector switch to MANUAL. It is also possible to
cancel the hold shift by turning the starting switch OFF.

FRONT WIPER SWITCH 0.

When rotary switch (A) of this switch (16) is turned, the front
wiper will move.
If push button (B) is pressed, washer liquid will be sprayed out
onto the front glass while the button is being pressed. Display
window
Position(a): (OFF) stop
Position(b): (INT)Intermittent wiper
Position(c): Low-speed wiper
Position(d): High-speed wiper
Push Rotary
button switch

REAR WIPER SWITCH 0.

When lever (C) of this switch (17) is turned, the rear wiper will
move.

Position (a): Washer liquid is sprayed out

Position (b): OFF Lever
Position (c): Wiper is operated
Position (d): Washer liquid is sprayed out, wiper is operated

3-42
OPERATION SWITCHES

CIGARETTE LIGHTER 0.
This is used to light cigarettes.
After cigarette lighter (18) is pushed in, it will return to its origi-
nal position after a few seconds, so pull it out and light your cig-
arette.

ROOM LAMP SWITCH 0.

The switch (19) is used to turn the room lamp ON and OFF.
Position (a): OFF
Position (b): Lights up when the cab door opens
Position (c): Lights up

REMARK
The room lamp lights up even when the main switch is
OFF, so when leaving the operator’s compartment, turn
the switch to position (a) (OFF) or (b).
When operating with the cab door fully open, set the
switch to position (a) (OFF).

REAR HEATED WIRE GLASS SWITCH 0.

When this switch (20) is pressed, electric current flows through
the heated wire glass at the rear and the mist is removed from
the glass.
Position (a): ON (removes mist from glass)
Position (b): OFF

3-43
SWITCHES OPERATION

E.C.S.S. SWITCH 0.

WARNING
If the machine is traveling or the work equipment is raised, the moment the E.C.S.S. switch is turned
ON, the work equipment will move.
If operations are carried out with the E.C.S.S. switch at the ON position, the moment the E.C.S.S.
switch is operated, the work equipment may move.
Never turn on the E.C.S.S. switch ON during inspection or maintenance. The work equipment will
move and this will create a dangerous situation.

NOTICE
Always stop the machine and lower the work equipment to the ground before operating the E.C.S.S.
switch.
When carrying out inspection and maintenance, first lower the work equipment to the ground, then turn
the E.C.S.S. switch OFF before starting the inspection and maintenance operation.
When carrying out leveling work, turn the E.C.S.S. switch OFF.

This switch (21) is used to turn the E.C.S.S. ON and OFF.

Position (a): ON
The pilot lamp lights up and the E.C.S.S. is actuated.
Position (b): OFF
The E.C.S.S. is not actuated.

REMARK
The E.C.S.S. is a device that uses the hydraulic spring effect of an accumulator to absorb the vibration
of the chassis during travel and allows the machine to travel smoothly and at high speed.
When traveling in 1st, the E.C.S.S. is not actuated.
When the speed range is 2nd to 4th, and the travel speed becomes more than 5 km/h, the E.C.S.S. is
automatically actuated; when the travel speed goes below 3 km/h, it is automatically disengaged.

EMERGENCY STEERING SWITCH 0.

This switch (22) is the manual control switch for the emergency
steering.
Even when the engine has stopped, steering operations are
made possible by pressing this switch.
Position (a): ON
The pilot lamp inside the switch and the emergency steering
pilot lamp on the machine monitor light up and it becomes
possible to operate the steering.

When the switch is released, it automatically returns to its origi-

nal position.

Actuate the emergency steering only in cases of emergency or when checking the function.

The time for operating the emergency steering continuously is a maximum of 60 seconds.
When using the emergency steering, travel at a speed of less than 5 km/h.
For details, see “EMERGENCY STEERING (3-93)“ in the OPERATION section.

3-44
OPERATION SWITCHES

COOLING FAN REVERSE ROTATION SWITCH 0.

This switch (23) is used to rotate the cooling fan in the reverse
direction when cleaning the radiator.
Position (a): ON
The pilot lamp inside the switch and the cooling fan reverse
rotation pilot lamp on the machine monitor light up. At the
same time, “COOLING FAN REVERSE“ is displayed on the
character display, and the fan is set to rotate in reverse.
Position (b): OFF
The cooling fan is set to rotate in the normal direction.

Stop the engine before operating the switch.

Switching normal rotation -> reverse rotation: With the engine stopped, do as follows: Starting switch ON ->
reverse rotation switch ON -> check machine monitor -> starting switch START -> fan reverse rotation
Switching reverse rotation -> normal rotation: Engine at low speed -> starting switch OFF -> starting switch ON ->
reverse rotation switch OFF -> starting switch START -> fan normal rotation

For details, see “CLEAN FINS BY ROTATING COOLING FAN IN REVERSE (4-28)“ in the WHEN REQUIRED
section.

REMARK
When the engine is running, even if the switch is pressed, the direction of rotation of the fan does not
change, but the cooling fan reverse rotation pilot lamp on the machine monitor flashes.
Use the reverse rotation of the fan only for cleaning. For normal operations, rotate the fan in the nor-
mal direction. If operations are carried out with the fan rotating in the reverse direction, the machine
will not display its full function and will tend to overheat.

Direction control switch for machines with 2-lever control 0.

(option)
This switch (24) is used to switch the direction of travel of the
machine between forward and reverse.
F Position: FORWARD
N Position: Neutral
R Position: REVERSE
Before operating this switch, check that the condition is as fol-
lows.
Directional lever is at N
Directional selector switch actuation switch is at ON
If the condition is not as above, the switch will not work.
For details, see “CHANGING DIRECTION (3-88)“.

DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH 0.

(option)
When this switch (25) is turned on, the directional selector
switch on the side of the lift arm control lever is actuated.
Position (a): ON
The directional selector switch is actuated.
The directional selector pilot lamp on the machine monitor
lights up.
Position (b): OFF
The directional selector switch is turned off.

3-45
SWITCHES OPERATION

SEMI AUTO DIGGING SWITCH 0.

(option)
For details, see “EPC WORK EQUIPMENT LEVER (6-55)“ in the ATTACHMENT AND OPTIONS section.

REMOTE POSITIONER RAISE MODE SWITCH 0.

(option)
For details, see “EPC WORK EQUIPMENT LEVER (6-55)“ in the ATTACHMENT AND OPTIONS section.

REMOTE POSITIONER LOWER MODE SWITCH 0.

(option)
For details, see “EPC WORK EQUIPMENT LEVER (6-55)“ in the ATTACHMENT AND OPTIONS section.

REMOTE POSITIONER RAISE/LOWER SET SWITCH 0.

(option)
For details, see “EPC WORK EQUIPMENT LEVER (6-55)“ in the ATTACHMENT AND OPTIONS section.

AFTERCOOLER TILT SWITCH 0.

This switch (30) can be used to tilt the aftercooler electrically.
Use this when cleaning the cooler fins.
Position (a): Cooler is tilted 17 degrees
Position (b): Cooler is returned to original position

TORQUE CONVERTER LOCK-UP SWITCH 0.

(option)
For details of the torque converter lock-up, see “HANDLING TORQUE CONVERTER LOCK-UP (6-27)“ in the
ATTACHMENT AND OPTION section.

LOAD METER CANCEL SWITCH 0.

(option)
For details of the load meter, see “HANDLING LOAD METER (6-2)“ in the ATTACHMENT AND OPTION section.

LOAD METER SUBTOTAL SWITCH 0.

(option)
For details of the load meter, see “HANDLING LOAD METER (6-2)“ in the ATTACHMENT AND OPTION section.

3-46
OPERATION CONTROL LEVERS, PEDALS

CONTROL LEVERS, PEDALS 0.

NOTICE
The overview shows a machine with 2-lever control (positions 5 and 6). For machines with multifunction
lever (detail A), see HANDLING MULTIFUNCTION LEVER (6-40).

(1) Gearshift lever (5) Bucket control lever

(2) Directional lever (6) Lift arm control lever

(3) Gearshift lever stopper (7) Brake pedal

(4) Safety lock lever (for work equipment lever) (8 )Accelerator pedal

GEARSHIFT LEVER 0.
This lever (1) changes the speed range of the transmission.

MANUAL SHIFT 0.
This machine has a 4-FORWARD, 4-REVERSE speed trans-
mission.
Place the gearshift lever in a suitable position to obtain the
desired speed range.
1st and 2nd speeds are used for working.
3rd and 4th speeds are used for traveling.
However, when the gearshift lever stopper is being used, it is
impossible to shift to 3rd or 4th. Disengage the gearshift lever
stopper before trying to shift gear.
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th

3-47
CONTROL LEVERS, PEDALS OPERATION

REMARK
The length of the lever can be adjusted to 3 stages (posi-
tions (A), (B), (C)). To adjust the length, remove the screw
at the bottom of the lever knob, slide the knob to the Knob
desired position, then tighten the screw again.
(The lever is installed to position (B) when it is shipped Lever
from the factory.)
Screw

AUTOMATIC SHIFT 0.
Automatic gear shifting can be carried out in the 2nd through
4th speed range of the four forward and reverse speeds
depending on the travel conditions.
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th

The range of speeds during automatic gear shifting is deter-

mined by the position of the gearshift lever as shown in the
chart on the right.
lever position
Gear shift

NOTICE
The following describes a machine with 2-lever control. For
machines with multifunction lever, see HANDLING MULTI-
FUNCTION LEVER (6-40).
Automatic speed range

REMARK
The 1st position for the gearshift lever fixes the trans-
mission 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.
If the transmission is in auto-shift and the travel speed
is below 12.5 km/h in any speed range when traveling in
either forward or in reverse, the kick-down switch is
actuated and makes it possible to shift down to 1st.
This makes it easy to carry out load and carry opera-
tions.
Even if the travel speed is more than 12.5 km/h, this
switch can be used to shift the transmission down.
Each time the kick-down switch is pressed, the speed
range will shift down one range at a time (when in 4th:
F4 -> F3 -> F2; when in 3rd: F3 -> F2).

3-48
OPERATION CONTROL LEVERS, PEDALS

To set to the desired speed range when traveling uphill or

downhill, or when carrying out grading, do as follows.
When fixing the speed range
Press the HOLD switch on the lift arm control lever.
The speed range is fixed at the speed range displayed on
the transmission indicator on the main monitor.
When shifting up or down from set speed range
Shift gear with the gearshift lever.

REMARK
When the transmission has been shifted down from 2nd to 1st with the kickdown switch, it will shift up
from 1st to 2nd when the travel speed increases.

DIRECTIONAL LEVER 0.
This lever (2) is used to switch the direction of travel of the
machine between forward and reverse.
When starting the engine, if the directional lever is not at the N
position, the engine will not start.
In this case, the central warning lamp will light up and the
buzzer will sound.
At the same time, “E00 SHIFT LEVER NEUT“ is displayed on
the character display.
Return the gearshift lever to the N position and start the engine.
Position (a): FORWARD
Position N: NEUTRAL
Position (b): REVERSE

REMARK
The length of the lever can be adjusted to 3 stages (posi-
tions (A), (B), (C)). To adjust the length, remove the screw
at the bottom of the lever knob, slide the knob to the Knob
desired position, then tighten the screw again.
(The lever is installed to position (B) when it is shipped Lever
from the factory.)
Screw

GEARSHIFT LEVER STOPPER 0.

This stopper (3) prevents the gearshift lever from entering the
3rd or 4th positions when working.
Position (a): Stopper actuated.
Position (b): Stopper released.

3-49
CONTROL LEVERS, PEDALS OPERATION

SAFETY LOCK LEVER (FOR WORK EQUIPMENT LEVER) 0.

WARNING
Before standing up from the operator’s seat, set the safety lock lever securely to the LOCK position.
If the safety lock lever is not at the LOCK position, and work equipment control lever (A) is touched by
mistake, it may lead to a serious accident.
If the safety lock lever is not placed securely at the LOCK position, the work equipment may move,
and this may lead to a serious accident or personal injury. Check that the lever is in the position
shown in the diagram.
When pulling up or pushing down the safety lock lever, be careful not to touch work equipment con-
trol lever (A).

This lever (4) is a lock device for the work equipment control
lever.
Push the safety lock lever down to lock it.

REMARK
Free
This lever serves to shut off the hydraulic circuit for work
equipment. When it is kept at the LOCK position, the work
equipment does not move, even if work equipment control
lever (A) is operated. Lock

Actuating the work unit (2-lever control) 0.

NOTICE
The following describes a machine with 2-lever control. For machines with multifunction lever, see
HANDLING MULTIFUNCTION LEVER (6-40).

This lever (5) operates the bucket.

Position (a): TILT

When the bucket control lever is pulled further from the TILT
position, the lever is stopped in this position until the bucket
reaches the preset position of the positioner, and the lever
is returned to the HOLD position.
Position (b): HOLD
The bucket is kept in the same position.
Position (c): DUMP

Tilt

Dump

3-50
OPERATION CONTROL LEVERS, PEDALS

LIFT ARM CONTROL LEVER 0.

NOTICE
The following describes a machine with 2-lever control. For machines with multifunction lever, see
HANDLING MULTIFUNCTION LEVER (6-40).

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 pre-set position of the kick-out, and the
lever is returned to the HOLD position.
Position (b): HOLD
The lift arm is kept in the same position.
Position (c): LOWER
Position (d): FLOAT
The lift arm moves freely under external force.
l

Raise

Lower

BRAKE PEDAL 0.

WARNING
When traveling downhill, use the engine as a brake,
and always use the right brake pedal.
Do not use the brake pedals repeatedly unless neces-
sary.
Do not put your foot on this pedal unless necessary.

These pedals (7) operate the brakes.

RIGHT BRAKE PEDAL 0.

The right brake pedal operates the wheel brakes.
Use the right brake pedal for normal braking operations.

LEFT BRAKE PEDAL 0.

The left brake pedal operates the wheel brakes.
When the transmission cut-off switch is in the ON position, and if this brake pedal is depressed, wheel brakes are
applied and the transmission is set to the neutral position at the same time. If the transmission cut-off switch is at
OFF, the left brake pedal acts in the same way as the right brake pedal.

REMARK
When the accelerator is being used for operating the work equipment, always set the transmission cut-off
switch to the ON position and use the left brake pedal to slow or stop the machine.

3-51
STEERING TILT LOCK LEVER OPERATION

ACCELERATOR PEDAL 0.
This pedal (8) controls the engine speed and output.
The engine speed can be freely controlled between low idling
and full speed.

STEERING TILT LOCK LEVER 0.

WARNING
Stop the machine before adjusting the tilt of the steering
wheel. If this operation (adjustment) is carried out while
the machine is moving, it may lead to a serious accident
or personal injury.

This lever is used to unlock and lock the steering column when Free
Lock
adjusting the position of the steering column to the front or rear
or up or down.
Pull the lever up, set the steering wheel to the desired position,
then push the lever down to lock the steering column securely
in position.
The amount of adjustment is as follows.

Up-down When at When moved up to

movement 0 mm 40 mm

Tilt
0 - 105 mm 0 - 130 mm
amount

3-52
OPERATION CAP WITH LOCK

CAP WITH LOCK 0.

The fuel tank filler port and the hydraulic tank filler port (option) are equipped with locks.
Use the starting switch key to open and close the cap.

CAP WITH LOCK FOR THE FUEL TANK FILLER PORT 0.

TO OPEN THE CAP 0.
1. Insert the starting switch key into the cap as far as it will go
(to the shoulder).
If the starting switch key is turned before it is inserted all the
way, it may break.
2. Turn the starting switch key clockwise, align the match mark
on the cap with the rotor groove, then remove the cap.

Shoulder

LOCK
OPEN

TO LOCK THE CAP 0.

1. Screw the cap into place.
2. Turn the key counterclockwise and take the key out.

3-53
CAP WITH LOCK OPERATION

CAP WITH LOCK FOR THE HYDRAULIC TANK FILLER PORT 0.

(option)

TO OPEN THE CAP 0.

1. Insert the starting switch key into the cap as far as it will go
(to the shoulder).
If the starting switch key is turned before it is inserted all the
way, it may break.
2. Turn the starting switch key counterclockwise and bring the
rotor groove in line with the aligning mark on the cap. Turn
the cap slowly until a “clicking“ sound is made. This
releases the lock and allows the cap to be opened.
Shoulder

Lock
Open

Aligning
mark

TO LOCK THE CAP 0.

1. Screw the cap into place.
2. Turn the starting switch key counterclockwise and take the key out.

3-54
OPERATION SAFETY BAR

SAFETY BAR 0.

WARNING
When carrying out maintenance or transporting the
machine, always fit the safety bar. Free
Always remove the safety bar for general travel opera- Lock
tions. If it is not removed, the steering wheel cannot
be used for steering. This is extremely dangerous.

The safety bar is used during maintenance or when transport-

ing the machine. It locks the front and rear frames, and pre-
vents the front and rear frames from pivoting.

TOWING PIN 0.
1. Insert towing pin (1) into hole (2) in the counterweight.

2. Use linch pin (3) to set so that the towing pin does not come
out.

Carry out this operation in reverse to remove the pin.

GREASE PUMP 0.
The grease pump is stored inside the battery box at the rear of
the machine. After using it, wipe off all grease stuck to the out-
side of the pump and then store it in the box.
It can be stored in either the left or right battery box.

3-55
CAB DOOR OPEN LOCK OPERATION

CAB DOOR OPEN LOCK 0.

When getting in or out of the operator’s compartment, or when
operating with the door open, use this lock to hold the door in
position.
1. Push the door against catch (1) to fix it in position.
2. When fixing the door in position, fix it firmly to the catch.
3. When getting on or off the machine, hold the handrail on the
inside.

4. When closing the door from the operator’s seat, push lever
(2) up to release the catcher.
5. When closing the door after getting of the machine, push Free
lever (3) down to release the catcher.

Free

CAB WINDOW OPEN LOCK 0.

Use this knob when you want to move the door window glass
up or down to open or close it.
Grip lock cancel knob (1) to release the lock, and move it down
to a lower lock position. Release lock cancel knob (1).
There are 3 points for lock position (A).

BACKUP ALARM 0.
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.
If the alarm cannot be heard clearly or is too loud, adjust the volume as follows.

REMARK
The alarm is set to the highest level when the machine is shipped from the factory.

METHOD OF CHANGING 0.
Operate the sound pressure selector switch at the rear face of
the backup alarm to adjust the volume.

Sound pressure:
Medium
Sound pressure:
Low
Sound pressure:
High
Sound pressure
selector switch

3-56
OPERATION FUSE

FUSE 0.
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.

The fuses protect the electrical equipment and wiring from

burning out.
If the fuse becomes corroded, or white powder can be seen, or
the fuse is loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.

Loosen knob (1) at two places, then remove cover (2). The
fuse boxes are A and B.

FUSE CAPACITY AND NAME OF CIRCUIT 0.

FUSE BOX A 0.

Fuse
No.‚ Name of circuit
capacity

(1) 10A Horn, air suspension

(2) 20A Transmission control

(3) 10A Parking brake

(4) 10A Emergency steering

(5) 20A Work equipment positioner

(6) 20A Rear heated wire glass

(7) 20A Wiper, washer

(8) 10A Rotating lamp (option)

(9) 10A (KOMTRAX)

(10) 10A Backup lamp, brake lamp

Front of machine
(11) 20A Main lamp circuit

(12) 10A Right side clearance lamp

(13) 10A Left side clearance lamp

(14) 10A Right head lamp

(15) 10A Left head lamp

3-57
SLOW-BLOW FUSE OPERATION

FUSE BOX B 0.

Fuse
No. Name of circuit
capacity

(1) 20A Starting switch

(2) 10A Hazard lamp

(3) 10A Instrument panel A

(4) 10A Room lamp

(5) 10A Spare 1

(6) 20A Power mode selector motor

(7) 10A Turn signal indicator

(8) 20A Front working lamp

(9) 20A Rear working lamp

(10) 10A Instrument panel B Front of machine

(11) 10A Car radio

(12) 10A Spare 2

(13) 10A DC-DC converter

(14) 20A Air conditioner A

(15) 20A Air conditioner B

SLOW-BLOW FUSE 0.
If the power does not come on when the starting switch is
turned ON, the slow-blow fuse may be blown, so check and
replace it.
The slow-blow fuse is beside the engine on the left side of the
machine.

SLOW-BLOW FUSE
(1)120A: Heater relay (electrical intake air heater)
120A: Main power
(2)40A: Fuel cut-off power source
(3)30A: Battery power (starting switch, hazard)
30A: After cooler tilt power source (option)

3-58
OPERATION TAKING OFF POWER

TAKING OFF POWER 0.

NOTICE
There are two power sources: 12V and 24V
Check the voltage of the electrical equipment and select the appropriate power source.
Mistaken use, such as using 24V as the power source for 12V equipment, will cause failure of the
equipment.
When using the electric power source, do not install any equipment which will exceed the maximum
amperage.

When cigarette lighter (1) is removed, the lighter socket can be

used as a 24V power source.
Maximum amperage: 9A (216W)

Electric power source (2) can be used as a 12V power source.

Maximum amperage: 10A (120W)

3-59
AIR CONDITIONER OPERATION

AIR CONDITIONER 0.
(For cab)
By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it pos-
sible to provide a pleasant working environment even on dusty jobsites.

GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL 0.

DEF DEF

DEF DEF

FACE FACE

FOOT

Temperature level
indication lamp

(1) Fan switch (4) External/Internal air changeover switch

(2) Air conditioner switch (5) Temperature control switch

(3) Mode selector switch

FAN SWITCH 0.
This switch (1) can be used to adjust the air flow to four stages.
It also acts as the main switch for the air conditioner. When the
OFF switch is pressed, the fan stops.
When the switch is pressed, the indicator lamp above the
switch lights up to display the air flow.

3-60
OPERATION AIR CONDITIONER

AIR CONDITIONER SWITCH 0.

This switch (2) is used to start or stop the cooling or dehumidi-
fying 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.

MODE SELECTOR SWITCH 0.

This switch (3) is used to select the vents.
The following five vent modes are available: FACE, FACE/
FOOT, FOOT, FOOT/DEF, DEF.
When the switch is pressed, the indicator lamp above the
switch lights up to display the vent mode.

FRESH/RECIRC SELECTOR SWITCH 0.

This switch (4) changes between internal air circulation and external air intake.
When pressing the switch, the indicator lamp on the top of switch lights up.

Internal air circulation

This (4) is used when wishing to quickly cool or warm the cab
or when the air inside the cab is stale.

External air intake

This (4) is used to cool or warm the cab with the external air
intake. Also, it is used for fresh air intake or to remove conden-
sation on windows.

3-61
AIR CONDITIONER OPERATION

TEMPERATURE CONTROL SWITCH 0.

The temperature can be adjusted with this switch (5) steplessly
from low temperature to high temperature.
The temperature level indicator lamps light up to display the
temperature of the air coming from the vents.
The more the blue lamps light up, the lower the temperature is.

The color of the indicator lamp changes while the switch is

being pressed.
When the temperature reaches the desired level, release the
switch to set the temperature.
The settings for each mode are retained in memory even when
the starting switch is turned OFF.

However, in the following cases, the settings must be made again.

When the machine has been out of use for more than 7 days
When the battery voltage is extremely low
When there has been abnormal interference from outside
When the fan switch is turned OFF (the setting is not kept in memory with only the air conditioner switch)

If the air conditioner is used at the FRESH position, the inside of the cab will be pressurized and this will prevent
the entry of dust.
The higher the position of the fan switch, the more effective the pressurizing becomes.

METHOD OF OPERATION 0.

Switch FRESH/RECIRC
Air conditioner Temperature Mode selector
Fan switch air changeover
switch control switch switch
Condition of use switch
Rapid HI ON All blue RECIRC FACE
Cooling More than half
Normal HI - LO ON FRESH FACE
are blue

Dehumidifying, More than half

HI - LO ON FRESH FOOT
heating are red
Rapid HI OFF All red RECIRC FOOT
Heating More than half
Normal HI - LO OFF FRESH FOOT
are red

More than half

Defroster HI ON FRESH DEF
are red

Vetilation or pres-
HI - LO OFF All blue FRESH FACE
surizing

3-62
OPERATION AIR CONDITIONER

When carrying out the defrosting, if the temperature control

switch is set so that all lamps are red, this will improve the per-
formance for defrosting and demisting.

Set the vent mode selector switch to the intermediate position

to give the desired condition.
With the FACE vents, it is possible to adjust the direction of the
air flow and to turn it on or off.
However, do not set to the FACE mode with the vents closed.

WHEN NOT USING THE AIR CONDITIONER REGULARLY 0.

Run the air conditioner at cooling or dehumidification + heating for several minutes from time to time to prevent the
loss of the oil film at various parts of the compressor.

REMARK
If the temperature inside the cab is low, the air conditioner may not work. In such cases, use the recircu-
lated air to heat up the inside of the cab, then turn the air conditioner switch on to run the air conditioner.

COOL BOX 0.
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.
Do not use the cool box for things which smell or leak water or
break easily.
Do not use it as a holder for tools or other small objects.

Vent grill

PRECAUTIONS WHEN USING 0.

PRECAUTIONS WHEN USING THE COOLING 0.
If you smoke when using the air conditioner, your eyes may start to itch or burn, therefore ventilate the cab
every so often to remove the smoke.
When using the air conditioner for a long period of time, then carry out ventilation process at least once every
hour.
When using the air conditioner, it is recommended for health reasons that it should only feel slightly cooler (5 or
6°C lower than the outside temperature) when you enter the cab.
Be careful then, to adjust the temperature to a suitable level.

3-63
CAB WIPER OPERATION

CAB WIPER 0.
PREVENTING DAMAGE TO WIPER ARM BRACKET 0.

NOTICE
When angling the wiper arm to the front, check that the Angle to front
wiper blade is hanging free. when
hanging
When angling the wiper arm to the front, such as when wiping loose
the glass clean, if the wiper arm is angled with the wiper blade
locked to the arm (the bottom of the blade is caught on the
arm), abnormal force is brought to bear on the mounting
bracket and the bracket may break.

DUST INDICATOR 0.
Open the engine side cover on the right side of machine. The
dust indicator is located at the lower part of the air cleaner.
The display is given in five stages according to the degree of
clogging of the element.

The air cleaner clogging caution lamp on the machine monitor

lights up when the air cleaner is clogged to inform the operator
that the air cleaner should be cleaned.
After cleaning, press the reset button to cancel the display.

For details of the method of cleaning, see “CLEANING OUTER

ELEMENT (4-19)“.

3-64
OPERATION CHECK BEFORE STARTING

OPERATION 0.
NOTICE
The following describes a machine with 2-lever control. For machines with multifunction lever, see
HANDLING MULTIFUNCTION LEVER (6-40).

CHECK BEFORE STARTING 0.

WALK-AROUND CHECK 0.

WARNING
Always attach the warning tag to work equipment con-
trol lever (1).
Leakage of oil or fuel, or accumulation of flammable
material around high temperature parts, such as the
engine muffler or turbocharger, may cause fire.
Check carefully, and if any abnormality is found,
repair it or contact your Komatsu distributor. 9JA03034-A

Before starting the engine, walk around the machine and look to the underside of chassis for anything unusual like
looseness of the bolts and nuts, leakage of fuel, oil and cooling water. Also check the condition of the work equip-
ment and the hydraulic system.
Check also for loose wiring, play, and collection of dust at places which reach high temperature.
Always carry out the items in this section before starting the engine each day.
1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses
Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses. If
any abnormality is found, repair it.
2. Remove dirt and dust from around engine, battery, radiator
Check if there is any dirt or dust accumulated around the engine or radiator. Check also if there is any flamma-
ble material (dead leaves, twigs, etc.) accumulated around the battery or high temperature engine parts, such
as the engine muffler or turbocharger. Remove all such dirt or flammable material.
3. Check for leakage of water or oil around engine
Check that there is no leakage of oil from the engine or leakage of water from the cooling system. If any abnor-
mality is found, repair it.
4. Check for leakage of oil from transmission case, axle, hydraulic tank, hoses, joints.
Check that there is no leakage of oil. If any abnormality is found, repair the location of the leakage.
5. Check for leakage of oil from brake line
Check that there is no leakage of oil. If any abnormality is found, repair the location of the leakage.
6. Check for damage or wear to tires, loose mounting bolts
Check for cracks or peeling of the tires and for cracks or wear to the wheels (side rim, rim base, lock ring).
Tighten any loose wheel nuts. If any abnormality is found, repair or replace the part.
If any valve caps are missing, install new caps.
7. Check for damage to handrail and steps, loose bolts
Repair any damage and tighten any loose bolts.
8. Check for damage to gauges, lamps on instrument panel, loose bolts
Check for damage to the panel, gauges and lamps. If any abnormality is found, replace the parts. Clean off any
dirt on the surface.
9. Check for loose air cleaner mounting bolts
Check for the loose bolts, and if loose, tighten up.
10.Check for loose battery terminals
Tighten any loose terminal.

3-65
CHECK BEFORE STARTING OPERATION

11. Check for damage to seat belt and mounting clamps.

Check that there are no loose bolts on the equipment

mounting the seat belt to the machine, and tighten if neces-
sary.

If the belt is damaged or fluff is starting to form, or if there is

any damage or deformation of the seat belt holders, replace
the seat belt with a new part.

GK015036

12.Clean cab window

Clean the cab window to ensure good visibility when operating the machine.

13.Inspection of tires

WARNING
If worn or damaged tires are used, they may burst and
cause serious injury or death.
To ensure safety, do not use the following tires.
Wear:
Tires with a tread groove of less than 15% of that of a Cord
new tire
Tires with extreme uneven wear or with stepped-type
wear Bead
Damage:
Tires with damage which has reached the cords, or
with cracks in the rubber
Tires with cut or pulled cords
Tires with peeled (separated) surface
Tires with damaged bead
Leaking or improperly repaired tubeless tires
Deteriorated, deformed or abnormally damaged tires
which do not seem usable.

14.Inspection of rims

WARNING
Check the rims (wheels) and rings for deformation, corrosion and cracks.
In particular, check the side rings, lock rings and rim flanges thoroughly.

3-66
OPERATION CHECK BEFORE STARTING

CHECK BEFORE STARTING 0.

Always carry out the items in this section before starting the engine each day.

CHECK MONITOR PANEL 0.

1. Turn the starting switch ON.

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 dis-
connection, so contact your Komatsu distributor for inspec-
tion.

3-67
CHECK BEFORE STARTING OPERATION

CHECK COOLANT LEVEL, ADD WATER 0.

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. Wait for the temperature to go down, then turn the cap slowly to release the pres-
sure before removing it.

CAUTION
When adding water, use the step and handrail provided, and support your body securely.

1. Open side door (1) of the engine hood on the right side of
the machine.
2. Look through inspection window (A) and check that the
water level is in the range between FULL and LOW on sub
tank (2). If the water level is low, open cover (3) and add
water through the filler port of sub tank (2) until it reaches
the FULL level.
3. After adding water, tighten the cap securely.
4. If sub tank (2) is empty, check for water leakage, then check
the water level in the radiator. If the water level is low, add
water to the radiator, then add water to sub tank (2).

If the volume of coolant added is more than usual, check for

possible water leakage.
Confirm that there is no oil in the coolant.

3-68
OPERATION CHECK BEFORE STARTING

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 0.

WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious
burns. Wait for the temperature to go down before starting the operation.

1. Open the inspection cover of the right side at the rear of the machine.
2. Take out the dipstick (G) and wipe off the oil with cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.
4. The oil level should be between the H and L marks on dip-
stick (G).
If the oil level is below the L mark, add engine oil through oil
filler (F).
5. If the oil is above the H mark, drain the excess engine oil
from drain plug (P), and check the oil level again.
6. If the oil level is correct, tighten oil filler cap (F) securely and
close the inspection window.

REMARK
When checking the oil level after the engine has been
operated, wait for at least 15 minutes after stopping the
engine before checking.
If the machine is at an angle, make it horizontal before
checking.

3-69
CHECK BEFORE STARTING OPERATION

CHECK FUEL LEVEL, ADD FUEL 0.

WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up com-
pletely. Never bring flames near fuel because it is highly flammable and dangerous.

NOTICE
If the engine has run out of fuel and has stopped, it is necessary to operate the priming pump to bleed the
air completely from the fuel line before starting the engine again.
Take care not to let the engine stop because of lack of fuel.
If the engine has run out of fuel, the air bleeding operation can be carried out more quickly if the fuel tank
is completely filled with fuel.

1. Turn the engine starting switch to the ON position and

check the fuel level with fuel level gauge (G).
After checking, turn the switch back to the OFF position.

2. After the day’s work is finished, open cover (1) and refill fuel
through fuel filler port (F) until the fuel tank is full.
For details of the method for opening and closing the cap,
see “CAP WITH LOCK (3-53)“.
3. After adding fuel, tighten the cap securely.

Fuel capacity: 300 liters

3-70
OPERATION CHECK BEFORE STARTING

CHECK ELECTRIC WIRINGS 0.

WARNING
If the fuses frequently blow or if there are traces of short circuits on the electrical wiring, locate the
cause immediately and carry out repairs, or contact your Komatsu distributor for repairs.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is
clogged with dirt or dust, wash the battery cap to clean the breather hole.

Check for damage and wrong capacity of the fuse and any sign of disconnection or short circuit in the electric wir-
ing. Check also for loose terminals and tighten any loose parts.
Check the wiring of the “battery“, “starting motor“ and “alternator“ carefully, in particular.
When carrying out checks around the battery, always check if there is any accumulation of flammable material
around the battery, and remove such flammable material.
Please contact your Komatsu distributor for investigation and correction of the cause.

CHECK PARKING BRAKE 0.

Check that the parking brake works properly.
If there is any abnormality in the operation of the parking brake or the brake does not provide the prorer braking
effect, please contact your Komatsu distributor for adjustment.

CHECK BRAKE PEDAL 0.

Drive the machine forward and check the effect of the brakes.
If there is any abnormality in the actuation of the brakes, please contact your Komatsu distributor to have the
brakes adjusted.

CHECK INFLATION PRESSURE OF TIRES 0.

Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.
Check for damage or wear to the tires and the rims.
Check for loose wheel hub nuts (bolts).
The proper inflation pressure is shown below.

Tire size Inflation pressure

20.5-25-16PR
Front Tire: 0.34 MPa (3.5 kgf/cm²)
(L3 Rock)
Rear Tire: 0.34 MPa (3.5 kgf/cm²)
(standard)

23.5-25-16PR
Front Tire: 0.30 MPa (3.1kgf/cm²)
(L3 Rock)
Rear Tire: 0.30 MPa (3.1kgf/cm²)
(option)

NOTICE
The optimum inflation pressure differs according to the type of work. For details, see “HANDLING THE
TIRES (3-109)“.

3-71
ADJUSTMENT BEFORE STARTING OPERATION

ADJUSTMENT BEFORE STARTING 0.

SEAT ADJUSTMENT 0.

WARNING
When adjusting the operator’s seat, stop the machine in a safe place before starting the operation.
Adjust the seat before starting operations for the day or when changing operators.
When adjusting the seat, put your back against the backrest and adjust to a position where the brake
pedal can be fully depressed.

Always adjust the operator’s seat before starting each oper-

ation or when the operators change shift.
When adjusting the seat, put your back against the backrest
and adjust to a position where the brake pedal can be fully
depressed.

(A) Horizontal adjustment 0.

Lift lever and move seat forwards/backwards.
Release the lever to lock the seat.

(B) Height and Slope adjustment 0.

Pull lever and adjust the seat position in height and slope by
loading/unloading the front/rear seat cushion area.

(C) Backrest adjustment 0.

Adjust the position of the backrest by pulling the lever whilst a
load is applied to the backrest.

(D) Weight adjustment 0.

Push button to adjust the suspension to the driver’s weight in
the middle swing position.
Careful! No height adjustment. B D E A C

(E) Lumbar support 0.

Push buttons to inflate/deflate the air chambers of the inte-
grated pneumatic system.
This allows the operator to match the shape of the backrest
individually to the body contours.

3-72
OPERATION ADJUSTMENT BEFORE STARTING

SAFETY BELT 0.

WARNING
Danger of injury! A damaged safety belt, a safety belt that has been stretched in an accident, or a
safety belt the belt fixings or fastening screws of which have not been mounted correctly will not pro-
tect you sufficiently in case of accident!
Replace the safety belt, if it is damaged, or if the machine has been involved in an accident. Check
that the belt fixings and fastening screws are in perfect condition, before you put on the safety belt.
If you have not put on the safety belt and are involved in an accident, this may lead to severe injuries!
Put on the safety belt, before you start work and do not take it off during work. Put on the safety belt
in such a way that it is not twisted and fits tightly.

The machine is provided with a lap belt which automatically

retracts. When pulled slowly, automatic belts ensure full free-
dom of action, but block immediately, if you suddenly brake or
accelerate, or if you drive downhill or take corners.

Putting on the safety belt 0.

1. Sit down on the driver’s seat.
2. Slowly and continuously pull out the belt (1).
3. Insert the lock tongue (2) into the lock socket (3) until the
lock engages.
4. Then, pull the belt to check whether or not the lock tongue is
fully engaged.
The belt cannot be pulled out unless it is completely wound
up.

Taking off the safety belt 0. 1

Press the orange button to release the lock of the safety belt
2
and allow the belt to wind up.

GK015036

3-73
ADJUSTMENT BEFORE STARTING OPERATION

ADJUST LEVER STAND 0.

Adjust height of wrist rest 0.

Loosen lock lever (2) and adjust the height of wrist rest (1).
Amount of adjustment: 55 mm

REMARK
Keep button (3) pressed and operate lock lever (2) to the
FREE position. The lever can be turned in the desired
direction.

Adjust angel of lever stand 0.

Operate lock lever (1) to the FREE position, grip the wrist rest
and tilt lever stand (2) to the front or rear, then return lock lever
(1) to the LOCK position.
Amount of adjustment: 65 mm

Free

Lock

ADJUST REAR VIEW MIRROR 0.

Sit in the operator’s seat and adjust the rear view mirror so that
you can see properly to the rear.
Be careful to have free visibility to the mirrors. Put no obstacles
in the view area.

3-74
OPERATION OPERATIONS BEFORE STARTING

OPERATIONS BEFORE STARTING 0.

NOTICE
The following describes a machine with 2-lever control. For machines with multifunction lever, see HAN-
DLING MULTIFUNCTION LEVER (6-40).

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 mistake
when starting the engine, the work equipment may move
unexpectedly and cause serious damage or personal
injury.

1. Check that parking brake switch (1) is at the ON position.

2. Check that directional lever (2) is at the N position.

When starting the engine, if directional lever (2) is not at the
N position, the engine will not start.

3. Lower the bucket to the ground, then check that work equip-
ment control lever (3) is locked by safety lock lever (4).

Free

Lock

3-75
OPERATIONS BEFORE STARTING OPERATION

4. Insert the key in starting switch (5), turn the key to the ON
position, and check that the machine monitor system works.

When the starting switch is turned to the ON position before

starting the engine, all the monitors, gauges, and central
warning lamp light up for approx. 3 seconds, and the alarm
buzzer sounds for approx. 1 sec.
If any monitor does not light up, there is probably a failure or
disconnection, so contact your Komatsu distributor for
inspection.
In addition, after all the monitors, gauges, and central warn-
ing lamp light up, a self check is carried out to check that the
emergency steering function works properly. For details,
see “EMERGENCY STEERING SELF-CHECK FUNCTION
(3-94)“ in the OPERATION section.

3-76
OPERATION STARTING ENGINE

STARTING ENGINE 0.
NORMAL STARTING 0.

WARNING
Check that there are no persons or obstacles in the
surrounding area, then sound the horn and start the
engine.
Exhaust gas is toxic. When starting the engine in con-
fined spaces, be particularly careful to ensure good
ventilation.

NOTICE
Do not accelerate the engine suddenly before complet-
ing the warming-up operation.
Do not keep the starting motor rotating continuously
for more than 20 seconds.
If the engine does not start, wait for at least 2 minutes
before trying to start the engine again.

1. Turn the key in starting switch (1) to the ON position. Pre-

heating will automatically start and preheating pilot lamp (2)
will light up.

The table shown below gives a guide to preheating time.

The preheating time in cold areas changes according to the

Preheating time

water temperature when starting the engine.

Water temperature when

starting the engine

3-77
STARTING ENGINE OPERATION

2. Depress accelerator pedal (3) lightly.

3. When preheating pilot lamp (2) goes out, turn the key in
starting switch (1) to the START position.
The starting motor will crank the engine and after 2 or 3 sec-
onds, the engine will start.
It takes a longer time than usual to start up the engine,
when the engine cooling water temperature is below 0°C
(32°F). In that case, keep the engine starting motor run-
ning, holding the key of engine starting switch (1) in the
SATART position, until the engine starts up.

4. After the engine starts, release the key in starting switch (1).
The key will automatically return to the ON position.

REMARK
Keep the accelerator pedal depressed after the engine
starts up, until engine warming-up run is finished. Do not
step on the pedal to the full stroke.

3-78
OPERATION STARTING ENGINE

STARTING IN COLD WEATHER 0.

WARNING
Check that there are no persons or obstacles in the
surrounding area, then sound the horn and start the
engine.
Exhaust gas is toxic. When starting the engine in con-
fined spaces, be particularly careful to ensure good
ventilation.

NOTICE
Do not suddenly accelerate the engine before the
warming-up operation is completed.

It takes some time to start up the engine when the machine is

left unused for more than half a day in the ambient temperature
of approx. -20°C. In that case, use the engine starting switch
and accelerator pedal in the following manner.
1. Turn the key in starting switch (1) to the ON position. Pre-
heating will automatically start and preheating pilot lamp (2)
will light up.

The table shown below gives a guide to preheating time.

The preheating time in cold areas changes according to the

Preheating time

water temperature when starting the engine.

Water temperature when

starting the engine
2. Depress accelerator pedal (3).

3-79
STARTING ENGINE OPERATION

3. When preheating pilot lamp (2) goes out, turn the key in
starting switch (1) to the START position.

4. There are two ways of starting up the engine in the ambient

temperature of approx. -20°C as introduced below.

Engine starting-up through single operation of engine starting motor

Stop the engine starting motor (release the engine starting switch), as the engine speed rises, and keep step-
ping on the accelerator pedal until the engine is fully running.

The engine starting motor must not be kept running for more than approx. 50 seconds.

Engine start-up through operating engine starting motor 2- 3 times

1) Keep the engine starting motor running for the max. 20 seconds, holding the key of engine starting switch
(1) in the START position, until the engine starts up.

2) If the engine fails to start up even after running the engine starting motor for about 20 seconds, stop the
engine starting motor once (release the engine starting switch key), and try the same process again after a
pause for a minute or so.

3) If the engine still fails to start up after the second attempt, try the same process for the third time after a
pause for a minute or so.

4) When the engine has started up and the engine speed

rises, release the key of engine starting switch (1). The
key will automatically return to the ON position.
5) Keep stepping on accelerator pedal (3) until the engine
is fully running.

REMARK
Keep the accelerator pedal depressed after the engine
starts up, until engine warming-up run is finished. Do not
step on the pedal to the full stroke.

3-80
OPERATION CHECKS AFTER STARTING

CHECKS AFTER STARTING 0.

WARNING
Emergency stop
If the operation is abnormal or any other trouble occurs, turn the key in the starting switch to the OFF
position.
If the work equipment is operated without warming up the machine sufficiently, the response of the
work equipment to the movement of the control lever will be slow, and the work equipment may not
move as the operator desires, so always carry out the warming-up operation. Particularly in cold
areas, be sure to carry out the warming-up operation fully.

BREAKING IN THE MACHINE 0.

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 breaking-in the machine for the initial 100 hours (as indicated by the service meter).
During breaking-in operations, follow the precautions described in this manual.

Idle the engine for 5 minutes after starting it up.

Avoid operation with heavy loads or at high speeds.
Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of emergency.

NORMAL OPERATION 0.
After starting the engine, do not immediately start operations. First, carry out the following operations and checks.

NOTICE
Do not suddenly accelerate the engine before the warm-
ing-up operation is completed.
Do not run the engine at low idling or high idling continu-
ously for more than 20 minutes.
If it is necessary to run the engine at idling, apply a load
from time to time or run the engine at a mid-range speed.

1. Depress accelerator pedal (1) lightly and run the engine

with no load at midrange speed for about 5 minutes.

3-81
CHECKS AFTER STARTING OPERATION

2. To warm up the hydraulic oil only in cold areas, do as fol-

lows. Hold
During the warming-up operation, check that the engine Tilt
rotation is smooth, then set the safety lock lever of the work
equipment control lever to the FREE position and move the
bucket control lever in and out of the TILT position to warm Free
up the hydraulic oil.
The relief time at the tilt position should be a maximum of 10
seconds.
With this operation, the oil will reach the relief pressure and
this will warm up the hydraulic oil more quickly.
3. After carrying out the warming-up operation, check that the
gauges and caution lamps are normal.
If there is any abnormality, carry out maintenance or repair.
Run the engine under a light load until engine cooling water
temperature gauge (2) and torque converter oil temperature
gauge (3) are in the green range.
4. Check that there is no abnormal exhaust gas color, noise, or
vibration. If any abnormality is found, contact your Komatsu
distributor.

REMARK
The sound of the cooling fan rotation differs according to the following conditions, but this does not indi-
cate any abnormality.
The cooling fan speed increases when the hydraulic oil temperature, engine coolant temperature, or trans-
mission oil temperature are high.
However, when the cooling fan is rotating in reverse, it rotates at a fixed speed proportional to the engine
speed, regardless of any oil or coolant temperature.

3-82
OPERATION STOPPING ENGINE

STOPPING ENGINE 0.

NOTICE
If the engine is abruptly stopped before it has cooled
down, engine life may be greatly shortened. Conse-
quently, 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 gradu-
ally, then stop it.

1. Run the engine at low idling for about 5 minutes to cool

down gradually.
2. Turn the key of starting switch (1) to the OFF position to
stop the engine.
3. Remove the key from starting switch (1).

CHECKS AFTER STOPPING ENGINE 0.

1. Walk around the machine and check the work equipment, body work, and undercarriage, and check also for
leakage of oil and water.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
Remove any mud affixed to the undercarriage.

3-83
MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING OPERATION

MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING 0.

WARNING
When moving the machine off, check that the area around the machine is safe and sound the horn to
give a warning.
Do not allow anyone in the area around the machine.
Remove any obstacles from the travel path.
There is a blind spot at the rear of the machine, so be particularly careful when traveling in reverse.
When moving the machine off up a hill, turn the transmission cut-of switch OFF, depress the left brake
pedal, then depress the accelerator pedal and gradually release the brake pedal to let the machine
move off. This makes it possible to prevent the machine from rolling back.

PREPARATIONS FOR MOVING MACHINE 0.

1. Check that warning pilot lamp (1) is not lighted up.

2. Unlock the safety lever (4) for the control lever of the work
equipment.

3-84
OPERATION MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING

3. Lift the boom until the work equipment is in drive position,

as shown to the right.

4. Depress right brake pedal (5) and turn parking brake switch
(6) to the OFF (RELEASE) position to release the parking
brake.
Keep right brake pedal (5) depressed.

REMARK
If the parking brake is still actuated when parking brake
switch (6) is at the OFF (RELEASE) position, turn the park-
ing brake switch ON, then turn it OFF again.

5. Set speed control lever (7) to the desired position.

6. Set directional lever (8) to the desired position.

3-85
MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING OPERATION

7. Release right brake pedal (5), then depress accelerator

pedal (9) to move the machine off.

REMARK
When moving the machine off on a hill, turn transmission
cut-off switch (1) OFF, depress left brake pedal (2), operate
the gearshift lever to the low speed range, then depress
accelerator pedal (3) and gradually release left brake pedal
(2) to let the machine move off. This makes it possible to
prevent the machine from rolling back.

3-86
OPERATION CHANGING GEAR SPEED

CHANGING GEAR SPEED 0.

NOTICE
The following describes a machine with 2-lever control. For machines with multifunction lever,
see HANDLING MULTIFUNCTION LEVER (6-40).

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.

1 st
2 nd
3 rd Lever stopper
4 th

REMARK
This machine is equipped with the kick-down switch.
When the machine is traveling in 2nd, press the button
on the tip of the lift arm control lever to shift down to
1st.
We recommend use of the kick-down switch when carry-
ing out operations in 1st or 2nd, such as digging or load-
ing.
For details of the method of use, see “KICKDOWN
SWITCH (3-41)“.
This machine is equipped with an auto-shift system that
automatically shifts the gear. For details of the method
of use, see “TRANSMISSION SHIFT MODE SELECTOR
SWITCH (3-36)“ and “AUTOMATIC SHIFT (3-48)“.
If the gearshift lever is operated slowly or is stopped
between gear positions, “E01 MAINTENANCE“ may be
displayed on the character display. In this case, there
is no failure, but try to operate the gearshift lever so
that the gearshifting is completed within 2 seconds.

3-87
CHANGING DIRECTION OPERATION

CHANGING DIRECTION 0.
NOTICE
The following describes a machine with 2-lever control. For machines with multifunction lever,
see HANDLING MULTIFUNCTION LEVER (6-40).

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.
When switching between FORWARD and REVERSE,
depress the brake to reduce the travel speed suffi-
c i e n t l y, t h e n c h a n g e t h e d i r e c t i o n o f t r a v e l .
(Max.speed for changing direction: 12 km/h)
Forward
There is no need to stop the machine even when switching
between FORWARD and REVERSE. N
Place directional lever (1) in the desired position.
Reverse
REMARK
There is a directional selector switch (option) which makes
it possible to change the direction of travel by operating a
switch.

If an attempt is made to switch the direction between forward

and reverse while traveling at high speed (when using 3rd or
4th), if the travel speed and engine speed are in ranges I or II in
Engine speed (rpm)

the chart on the right, the central warning lamp will light up and
the buzzer will sound.
At the same time, “E00 OVERRUN PROTECT“ is displayed on
the character display.
If the alarm buzzer sounds, depress the brake immediately to
reduce the travel speed, then operate the directional lever to
switch between forward and reverse.

WHEN USING AUTO-SHIFT

If an attempt is made to switch the direction between forward and reverse when the auto-shift is ON, normally, the
gearshift range will switch F3 -> R2, F4 -> R2, or R3 -> F2, R4 -> F2 to make it possible to move the machine off
quickly.
However, if an attempt is made to shift between forward and reverse when the machine is traveling at high speed
such as shown in ranges I or II in the chart on the right, the central warning lamp will light up and the buzzer will
sound.
At the same time, “E00 OVERRUN PROTECT“ is displayed on the character display.
If the alarm buzzer sounds, depress the brake immediately to reduce the travel speed, then operate the directional
lever to switch between forward and reverse.
In particular, if it is attempted to switch between forward and reverse in range II, the gear range will not shift to 2nd,
but will switch F3 -> R3, F4 -> R4, or R3 -> F3, R4 -> F4. As a result, the reduction in travel speed will be less than
in range I, so care is necessary.
REMARK
If the directional lever is operated slowly or is stopped midway between the forward and reverse direc-
tions, “E01 MAINTENANCE“ may be displayed on the character display. In this case, there is no failure,
but try to operate the directional lever so that the change in direction is completed within 2 seconds.

3-88
OPERATION CHANGING DIRECTION

CHANGE BETWEEN FORWARD AND REVERSE 0.

(option)
1. Place the directional lever at the N position.

2. Turn on directional selector switch on the right side of

switching panel that enables directional selection.
Position (a): ON
Position (b): OFF
The two pilot lamps light up, i.e. one is the pilot lamp built in
the actuating switch and another is the directional selector
pilot lamp on the machine monitor.
Then the actuating switch enables the forward - reverse
shifting to function.

If the directional selector pilot lamp on the machine monitor

flashes, the switch or the lever is in one of the following condi-
tions. Set it to the correct position.
When directional lever is not at N position
If the directional lever is not at the N position, the pilot lamp
flashes, and at the same time, the central warning lamp
lights up and the alarm buzzer sounds. In addition, “E00
SHIFTLEVER NEUT“ is displayed on the character display.
In this condition, the machine will move forward or in
reverse according to the set position of the directional lever.
Return the directional lever to the N position.
When directional selector switch is at F or R when engine is
started
If the directional selector switch is at F or R, the pilot lamp flashes, and at the same time, the central warning
lamp lights up and the alarm buzzer sounds. In addition, “E00 SHIFT SW NEUT“ is displayed on the character
display.
In this condition, the engine will not start, so set the directional selector switch to N.
3. Press the directional selector switch on the side of the work
equipment control lever to the desired position.

3-89
STOPPING MACHINE OPERATION

STOPPING MACHINE 0.

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. Apply
the parking brake only after the machine has stopped.

1. Release accelerator pedal (1), then depress brake pedal (2)

to stop the machine.

2. Place directional lever (3) in N (neutral) position.

3. Turn parking brake switch (4) to ON to apply the parking

brake.

REMARK
When the parking brake is applied, the transmission is
automatically returned to neutral.

3-90
OPERATION TRANSMISSION CUT-OFF

TRANSMISSION CUT-OFF 0.
When the transmission cut-off switch is turned ON, the pilot
lamp lights up and the following transmission cut-off function is
actuated.
Position (a): OFF
Position (b): ON

When the left brake pedal is depressed, the brake is actuated,

and in addition, the transmission is shifted to neutral at the pre-
selected brake pedal depression position.

REMARK
The cut-off function is actuated only with the left brake pedal.
When the transmission cut-off switch is at the OFF position, the left brake pedal works in the same way
as the right brake pedal.
For details of adjusting the brake pedal depression position where the cut-off function is actuated, see
“ADJUSTING TRANSMISSION CUT-OFF (3-92)“.
Raise or lower the pre-selected brake pedal depression position to adjust the cut-off to match the type
of work.

When carrying out scooping-up work, lower the brake pedal

depression position for the cut-off (transmission shifted to
neutral). In this setting, the transmission driving force is cut
at a point where there is ample braking force, so this pre-
vents the machine from slipping down.

When approaching dump trucks during loading operations,

raise the brake pedal depression position for the cut-off
(transmission shifted to neutral). In this setting, the fine
control of the braking immediately before dumping the load
can be carried out with the brake only, so this makes it easy
to control and allows the machine to be brought to a soft
stop.

3-91
TRANSMISSION CUT-OFF OPERATION

ADJUSTING TRANSMISSION CUT-OFF 0.

CAUTION
Apply the parking brake before adjusting the transmission cut-off position.

In the transmission cut-off function, it is possible to adjust the depression position of the left brake pedal used to
shift the transmission to neutral.

1. Start the engine with starting switch (1), then set parking
brake switch (2) to the ON position.
2. Set transmission cut-off switch (3) to the ON position.
3. Depress left brake pedal (4) and set it to the desired posi-
tion to shift the transmission to neutral.

4. Press transmission cut-off set switch (5), then release it.

When the switch is released, the buzzer will sound with a
repeated short sound, and the cut-off position is set.

Method of canceling cut-off position

5. After the buzzer sounds in Step 4 of the adjustment proce-
dure, the transmission cut-off switch flashes for 2 seconds.
While it is flashing, press transmission cut-off set switch (5)
again and release it.
6. The buzzer will sound with a long sound and the adjusted
cut-off position is canceled.

STOPPING WHEN TRANSMISSION CUT-OFF IS ON 0.

When the transmission cut-off switch is at the ON position and the left brake pedal is depressed, the transmission
is shifted to neutral at the pre-selected brake pedal depression position.
The transmission is not shifted to neutral when the right brake pedal is operated.

REMARK
When the transmission cut-off switch is OFF, the left brake pedal acts in the same way as the right brake
pedal, and the transmission is not shifted to neutral.

3-92
OPERATION TURNING

TURNING 0.
WARNING
Operating the steering wheel suddenly at high speed or operating the steering wheel on steep slopes
is dangerous. Do not operate the steering wheel in such situations.
If the engine stops when the machine is traveling, the emergency steering is actuated. Note that this
system is only for steering in emergencies, so never stop the engine.
It is particularly dangerous if the engine stops when the machine is traveling on slopes, so never let the
engine stop when traveling on slopes.
If the engine stops, stop the machine immediately at a safe place.

When traveling,use steering wheel (1) to turn the machine.

With this machine, the front frame is joined to the rear frame at
the center of the machine by the center pin. The front and rear
frames bend at this point, and the rear wheels follow in the
same track as the front wheels when turning.
Turn the steering wheel lightly to follow the machine as it turns.

NOTICE
When the steering wheel is turned fully, if it reaches the
end of its stroke, do not try to turn it further.
Check that there is a play of 50 to 100 mm in the steering
wheel. Check also that the steering works properly. If any
abnormality is found, please contact your Komatsu distrib-
utor for inspection.

EMERGENCY STEERING 0.

CAUTION
Never actuate the emergency steering except during
emergencies or when checking the function.
The emergency steering can be used continuously for
a maximum of 60 seconds. Operating it continuously
for more than 60 seconds may damage the system.
When using the emergency steering, travel at less
than 5 km/h.

During emergencies or when stopping the engine to check the

function, press emergency steering switch (1). Emergency
steering pilot lamp (green) (2) will light up and the steering can
be operated.

Emergency steering pilot lamp (green) (2) lights up to inform

the operator that the emergency steering system has been
actuated.
The emergency steering system is provided to enable the
machine to be steered under the following conditions.

The starting switch is at the ON position.

The steering oil pressure is low or there is no pressure.
(When the engine has stopped or there is a failure in the steering oil pressure pump, etc.)

When the starting switch is turned to the ON position, the emergency steering automatically carries out a self
check for 3 seconds. For details, see “EMERGENCY STEERING SELF-CHECK FUNCTION (3-94)“.

3-93
TURNING OPERATION

When the emergency steering controller detects lack of oil

pressure in the steering system, steering oil pressure caution
lamp (red) (3) and central warning lamp (4) light up, and the
alarm buzzer sounds intermittently.
When this happens, if the machine is traveling at a speed of
more than 2 km/h, the electric pump motor is automatically
actuated and emergency steering pilot lamp (green) (2) lights
up.
Steering oil pressure caution lamp (red) (3) lights up to inform
the operator that there is a failure in the steering system.
If steering oil pressure caution lamp (red) (3) lights up, move
the machine immediately to a safe place and stop it.
Locate the cause and do not operate the machine until it has been repaired.

REMARK
If any function of the oil pressure system is used when the engine is running at low speed, steering oil
pressure caution lamp (red) (4) may light up for a moment, but if the lamp goes out again soon, there is no
problem.

When the emergency steering controller detects that the oil pressure in the steering circuit has been restored, the
actuation of the emergency steering system is stopped.

EMERGENCY STEERING SELF-CHECK FUNCTION 0.

When the starting switch is turned ON, the emergency steering is automatically actuated for approx. 3 seconds to
check that the emergency steering is functioning properly.
When this happens, steering oil pressure caution lamp (red) (1)
and emergency steering pilot lamp (green) (2) light up.
The emergency steering function check is not carried out in the
following cases.
If the starting switch is turned ON, turned OFF again without
starting the engine, and is then turned ON again.
If the starting switch is turned ON again immediately after
stopping the engine when the steering oil pressure has not
gone down completely.
When automatic preheating is being carried out.

WHEN AUTOMATIC PREHEATING IS BEING CARRIED OUT

When automatic preheating is being carried out, the emergency steering self- check function is not actuated.
To check the emergency steering function, press the emergency steering switch after completing the warming-up
operation.

3-94
OPERATION OPERATION OF WORK EQUIPMENT

OPERATION OF WORK EQUIPMENT 0.

NOTICE
The following describes a machine with 2-lever control. For machines with multifunction lever, see HAN-
DLING MULTIFUNCTION LEVER (6-40).

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 0.

Position (a): RAISE
Position (b): HOLD
The lift arm is kept in the same position.
Position (c): LOWER
Position (d): FLOAT
The lift arm moves freely under external force.

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 kick-out position, and the lever is return to
the hold position.

NOTICE
Do not use the FLOAT position when lowering the bucket.
Use the FLOAT position when leveling works, see “LEVEL- Raise
ING OPERATIONS (3-99)“.

Lower

BUCKET CONTROL LEVER 0.

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.

Tilt

Dump

3-95
WORKING POSSIBILITY OPERATION

WORKING POSSIBILITY 0.
In addition to the following, it is possible to further increase the range of applications by using various attachments.

DIGGING OPERATIONS 0.
For machines equipped with an EPC work equipment lever (option), refer to the section of “SEMI AUTO DIGGING
OPERATIONS (6-57)“ in the chapter, ATTACHMENT AND OPTION, in this manual.

WARNING
Never carry out digging or scooping operations with the machine articulated. There is danger that the
machine may tip over.
When the machine is traveling or the work equipment is raised, the moment that the travel damper
switch is turned ON, the work equipment will move.

NOTICE
If the tires slip,the tire life will be reduced, so do not allow the tires to slip during operation.

LOADING PILED SOIL OR BLASTED ROCK 0.

When loading piled soil or blasted rock,drive the machine forward as follows to load. To prevent cutting of the
tires caused by the tires slipping, be careful of the following points during the operation.
Always keep the operating jobsite flat, and remove any fallen rocks.
When working with stockpiles, operate the machine in 1st or 2nd gear; when loading blasted rock operate
the machine in 1st gear.

1. When driving the machine forward and lowering the bucket,

stop the bucket about 30 cm from the ground, then lower it
slowly.

REMARK
If the bucket hits the ground,the front tires will come off
the ground, and the tires will slip.

2. Shift down immediately in front of the material to be loaded.

When completing the shift down, depress the accelerator Stockpile
pedal at the same time and thrust the bucket into the mate-
rial.

REMARK
To reduce fuel consumption, depress the accelerator
pedal the minimum possible amount. If it is depressed
fully, the fuel consumption will increase, but there will be
no increase in the amount loaded.

3. When the material is in a stockpile,keep the cutting edge of

the bucket horizontal; when loading blasted rock, have the
bucket tilting slightly down. Stockpile

Be careful not to get blasted rock under the bucket. This

will make the front tires come off the ground and slip.
Try to keep the load in the center of the bucket; if the load is
on one side of the bucket, the load will be unbalanced.

3-96
OPERATION WORKING POSSIBILITY

4. At the same time as thrusting the bucket into the material,

raise the lift arm to prevent the bucket from going in too far.
By raising the lift arm, ample traction will be produced by the
front tires.

REMARK
If the bucket is thrust too much and the lift arm stops ris-
ing or the machine stops moving forward, release the
accelerator pedal a little. Proper operation of the accelera-
tor pedal for each type of the soil is effective for saving of
fuel and prevention of wear of the tires.

5. Check that there is enough material loaded into the bucket,

then operate the bucket control lever to tilt the bucket and
load the bucket fully.

REMARK
If the bucket edge is moved up and down while pushing in
the bucket and digging, the front tires will come off the
ground and this will cause the tires to slip.

6. If there is too much material loaded in the bucket, dump and

tilt the bucket quickly to remove the excessive load. This
prevents spillage of the load during hauling.

3-97
WORKING POSSIBILITY OPERATION

DIGGING AND LOADING ON LEVEL GROUND 0.

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.

CAUTION
Do not set the bucket facing down more than 20 degrees.

1. Set the edge of the bucket facing slightly down.

2. Drive the machine forward and operate the lift arm control
lever forward to cut a thin layer of the surface each time
when excavating the soil.

3. Operate the lift arm control lever slightly up and down to

reduce the resistance when driving the machine forward.

When digging with the bucket, avoid imposing the digging

force onto only one side of the bucket.

3-98
OPERATION WORKING POSSIBILITY

LEVELING OPERATIONS 0.

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.
Turn the E.C.S.S. OFF when carrying out leveling opera-
tions.

1. Scoop soil into the bucket. Move the machine backward

while spreading soil from the bucket little by little.
2. Go over the spread soil with the bucket teeth touching the ground and level the ground by back-dragging.
3. Scoop some more soil into the bucket, put the lift arm control lever in FLOAT position, level the bucket at
ground level, and smooth the ground by moving backward.

PUSHING OPERATION 0.

CAUTION
Never set the bucket to the DUMP position when carrying out pushing operation.

When carrying out pushing operations, set the bottom of the bucket parallel to the ground surface.

LOAD AND CARRY OPERATIONS 0.

WARNING
When carrying a load, lower the bucket to lower the
center of gravity when traveling.
When the machine is traveling or the work equipment
is raised, the moment that the E.C.S.S. switch is
turned ON, the work equipment will move.

The load and carry method for wheel loaders consists of a

cycle of scooping -> hauling ->loading (into a hopper, glory
hole, etc.)
Always keep the travel path properly maintained.
When using the load and carry method, see “PRECAUTIONS FOR USING LOAD AND CARRY METHOD (3-
110)“.

3-99
WORKING POSSIBILITY OPERATION

LOADING OPERATIONS 0.
Select the method of operation which will give the minimum amount of turning and travel in order to provide the
most efficient method for the jobsite.

WARNING
Always keep the jobsite flat, and do not operate the steering wheel suddenly or apply the brakes sud-
denly when the lift arm is raised with a loaded bucket. This is dangerous.
Never thrust the bucket in when traveling at high speed (when loading soil or crushed rock). This is
dangerous.
When the machine is traveling or the work equipment is raised, the moment that the E.C.S.S. switch is
turned ON, the work equipment will move.

NOTICE
If the tires slip, the tire life will be reduced, so do not allow the tires to slip during operation.
Avoid excessive shaking of the bucket.

CROSS DRIVE LOADING 0.

Always set the wheel loader facing at a right angle to the stock-
pile. After digging in and scooping up the load, drive the
machine straight back in reverse, then bring the dump truck in
between the stock pile and the wheel loader.
This method requires the least time for loading, and is
extremely effective in reducing the cycle time.

3-100
OPERATION WORKING POSSIBILITY

V-SHAPE LOADING 0.
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.
The smaller the turning angle of the wheel loader is, the more
efficient the operation becomes.
When loading a full bucket and raising it to the maximum
height, first shake the bucket to stabilize the load before raising
the bucket. This will prevent the load from spilling to the rear.

PRECAUTIONS WHEN PILING UP LOADS 0.

When forming products into a pile, be careful not to let the rear counterweight come into contact with the ground.
Do not set the bucket to the DUMP position when carrying out piling-up operations.

REMARK
When carrying out scooping-up work, avoid using the transmission cut-off function as far as possible.
It will prevent the machine from moving back.
When using the transmission cut-off function, lower the cut-off position so that cut-off function is actu-
ated, when the brake pedal is deeply depressed, while ensuring ample braking force.

3-101
PRECAUTIONS FOR OPERATION OPERATION

PRECAUTIONS FOR OPERATION 0.

PERMISSIBLE WATER DEPTH 0.
When working in water or on swampy ground, do not let the
water come above the bottom of the axle housing. Axle housing
After finishing the operation,wash and check the lubricating
points.

IF WHEEL BRAKE DOES NOT WORK 0.

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.

PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES 0.

LOWER THE CENTER OF GRAVITY WHEN TURNING. 0.
When turning on slopes, lower the work equipment to lower the center of gravity before turning. It is dangerous to
turn the machine suddenly on slopes.

BREAKING ON DOWNHILL SLOPE 0.

If the footbrake is used frequently when traveling downhill, the brake will overheat and may be damaged. Place
the gearshift lever at a low speed range and use the braking force of the engine when traveling downhill.
Use the right brake pedal for braking.

If the brakes are used excessively, the axle oil temperature caution lamp may light up and the alarm buzzer may
sound intermittently. For details of the necessary action to take, see “AXLE OIL TEMPERATURE CAUTION LAMP
(3-16)“ in EXPLANATION OF COMPONENTS.

If the speed range selected by the gearshift lever is not correct, the torque converter oil may overheat. If this hap-
pens, shift down one gear range and reduce the oil temperature.
If the oil temperature does not return to the white range even when the gearshift lever is at 1st, stop the machine,
return the directional lever to the N position, and run the engine at a mid-range speed until the gauge returns to the
white range.

IF ENGINE STOPS 0.
If the engine stops on a slope, apply the parking brake immediately, and lower the work equipment to the ground
and stop the machine. Then put the directional lever in neutral position, and start the engine again.

3-102
OPERATION PRECAUTIONS FOR OPERATION

PRECAUTIONS WHEN DRIVING MACHINE 0.

When the machine travels at high speed for a long distance, the tires become extremely hot. This causes early
wear of the tires, so it should be avoided as far as possible. If the machine must be driven for a long distance, take
the following precautions.
Follow the regulations related to this machine, and drive carefully.
Before driving the machine, carry out the checks before starting.
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. (20.5-25-16PR)
Tire pressure
Front wheel: 0.34 MPa (3.5 kgf/cm²)
Rear wheel: 0.34 MPa (3.5 kgf/cm²)
Speed:14 km/h
Check the tire pressure before starting, when the tire is cool.
For longer drives, breaks have to be taken at regular intervals, otherwise the tires will be damaged. Ask your
tire dealer for drive and break times for the tire type on your machine.
During each break, inspect the tires and other parts for damages and check the oil and cooling medium levels.
Always travel with the bucket empty.
Never put “calcium chloride“ or “dry ballast“ in the tires when traveling.

PRECAUTIONS REGARDING BRAKE FUNCTION 0.

When traveling long distances continuously downhill, the frequency of using the brake may increase. As a result,
depending on the weight of the machine and the grade of the slope, the machine's braking capacity may be
exceeded and the brakes may overheat.
The table below shows a guideline of the values for this machine.

Machine Slope Braking capacity limit

weight grade Average travel speed Downhill distance limit
(t) (%) limit (km/h) (continuous)(km)

16.5 - 18.5 10 40 2
(unloaded) 20 15 0.7

21.6 - 23.6 10 30 1.5

(loaded) 20 12 0.5

If the braking capacity limit is exceeded, a forced cooling system for the brakes is needed, so please consult your
Komatsu distributor.

3-103
ADJUSTING WORK EQUIPMENT OPERATION

ADJUSTING WORK EQUIPMENT 0.

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.

The boom kickout makes it possible to set the bucket so that it

automatically stops at the desired lifting height (lift arm higher Free
than horizontal) and the bucket positioner makes it possible to Lock
set the bucket so that it automatically stops at the desired dig-
ging angle. The setting can be adjusted to match the working
conditions.

For machines equipped with an EPC work equipment lever

(option), refer to the section of “METHOD OF REMOTE POSI-
TIONER (6-58)“ in the chapter, ATTACHMENT AND OPTION,
in this manual.

ADJUSTING BOOM KICKOUT 0.

1. Raise the bucket to the desired height, set the lift arm con-
trol lever at HOLD and lock the lever in position with the
safety lock lever. Then stop the engine and adjust as fol-
lows.
2. Loosen two bolts (1), and adjust plate (2) so that the bottom
edge is in line with the center of the sensing surface of prox-
imity switch (3). Then tighten the bolts to hold the plate in
position.
3. Loosen two nuts (4) to make a clearance of 3 to 5 mm
between plate (2) and the sensing surface of proximity
switch (3). Then tighten the nuts to hold in position.
Tightening torque: 17.2 ± 2.5 N·m (1.75 ± 0.25 kgf·m)
4. After adjusting, start the engine and operate the lift arm control lever. Check that the lever is automatically
returned to HOLD when the bucket reaches the desired height.
5. Check the bucket position indicator.

3-104
OPERATION ADJUSTING WORK EQUIPMENT

ADJUSTING BUCKET POSITIONER 0.

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. Loosen 2 bolts (1), adjust the position of mounting bracket
(4) of the proximity switch so that the rear tip of bar (2) is in
line with the center of the sensing surface of proximity
switch (3), then tighten bolts to hold the bracket in position.
3. Loosen 2 bolts (5), adjust so that the clearance between bar
(2) and support (6) is 0.5 to 2 mm, then tighten bolts (5) to
hold in position.
4. Loosen 2 nuts (7), adjust so that the clearance between bar
(2) and the sensing surface of proximity switch (3) is 3 to 5
mm, then tighten the nuts to hold in position.
Tightening torque: 17.2 ± 2.5 N·m (1.75 ± 0.25 kgf·m)
5. After adjusting, start the engine and raise the lift arm. Operate the bucket control lever to the DUMP position,
then operate it to the TILT BACK position and check that the lever is automatically returned to the HOLD posi-
tion when the bucket reaches the desired digging angle.

BUCKET LEVEL INDICATOR 0.

(A) and (B) at the top rear of the bucket are the level indicators,
so the bucket angle can be checked during operations.
(A): Parallel with cutting edge
(B): 90 degrees to cutting edge

3-105
PARKING MACHINE OPERATION

PARKING MACHINE 0.
NOTICE
The following describes a machine with 2-lever control. For machines with multifunction lever, see HANDLING
MULTIFUNCTION LEVER (6-40).

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 fac-
ing directly down the slope, then dig the bucket into
the ground and put blocks under the tires to prevent
the machine from moving.
If the control lever is touched by accident, the work
equipment or the machine may move suddenly, and
this may lead to a serious accident. Before leaving
the operator’s compartment, always set the safety
lock lever securely to the LOCK position.
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. Apply the parking
brake only after the machine has stopped.

1. Release accelerator pedal (1), then depress brake pedal (2)

to stop the machine.

2. Place directional lever (3) in N (neutral) position.

3-106
OPERATION PARKING MACHINE

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.

Hold

Lower

5. Lock lift arm control lever (5) and bucket control lever (6)
with safety lock lever (7).

Free

Lock

3-107
CHECKS AFTER WORK OPERATION

CHECKS AFTER WORK 0.

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.

LOCKING 0.
Always lock the following parts.
(1) Fuel tank filler cap
(2) Engine side panel (2 points)
(3) Cab door (2 points)

REMARK
The starting switch key is used also for locks (1), (2), and
(3).

3-108
OPERATION HANDLING THE TIRES

HANDLING THE TIRES 0.

PRECAUTIONS WHEN HANDLING TIRES 0.

CAUTION Breaker or belt

(cord layer)
If a tire has reached any of the following service limits,
there is danger that the tire may burst or cause an acci- Tread
dent, so to ensure safety, replace it with a new tire.
Service limits for wear Shoulder
When the remaining depth of the groove on construction
equipment tires (at a point approx. 1/4 of the tread width)
is 15% of the groove depth on a new tire.
When the tire shows marked uneven wear, stepped
wear or other abnormal wear, or when the cord layer is
exposed. Inner liner
Service limits for damage
When there is external damage extending to the cord or Side wall Carcass
when the cord is broken
When the cord is cut or there is dragging
When the tire is peeling (there is separation)
When the bead is damaged
Bead
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 0.
Measure the tire pressure before starting operations, when the tires are cool.
If the tire inflation pressure is too low, there will be overload; if it is too high, it will cause tire cuts and shock burst.
To prevent these problems, adjust the tire inflation pressure according to the table on the next page.
Deflection ratio = H - h / H x 100
As a guideline that can be checked visibly, the deflection ratio
of the front tire (deflection/free height)is as follows.
When carrying normal load (lift arm horizontal): Approx. 15 to
25 %
When digging (rear wheels off ground): Approx. 25 to 35 %
When checking the tire inflation pressure, check also for small
scratches or peeling of the tire, for nails or pieces of metal
which may cause punctures, and for any abnormal wear.
Clearing fallen stones and rocks from the operating area and
maintaining the surface will extend the tire life and give
improved economy.
For operations on normal road surfaces, rock digging operations: High end of range in air pressure chart
Stockpile operations on soft ground: Average pressure in air pressure chart
Operations on sand (operations not using much digging force): Low end of range in air pressure chart

3-109
HANDLING THE TIRES OPERATION

If the deflection of the tire is excessive, raise the inflation pressure within the limits given in the table to give a suit-
able deflection (see deflection ratio).

Inflation pressure [MPa (kgf/cm²)]

H
Tire size Soft ground
Free height Normal road When shipped
(Pattern) (sandy ground)
(mm) from factory
Stockpile Stockpile Digging

20.5-25-16PR
(Standard)
387 (BS)
20.5-25-20PR
383 (TOYO)
(option) Front tire: 0.34
(L3 Rock) 0.26 - 0.37 0.27 - 0.44 0.27 - 0.44 (3.5)
20.5-25-16PR (2.6 - 3.8) (2.8 - 4.5) (2.8 - 4.5) Rear tire: 0.34
(option) (3.5)
386 (BS)
20.5-25-20PR
385 (TOYO)
(option)
(L2 Traction)

23.5-25-16PR
424 (BS)
(option) Front tire: 0.30
423 (TOYO)
(L3 Rock) 0.24 - 0.35 0.26 - 0.35 0.26 - 0.35 (3.1)
23.5-25-16PR (2.4 - 3.6) (2.6 - 3.6) (2.6 - 3.6) Rear tire: 0.30
434 (BS) (3.1)
(option)
422 (TOYO)
(L2 Traction)

Stockpile operations mean the loading of sand and other loose

materials.

The specified air pressure values might deviate from the stan-
dard values under special conditions. If this is the case, please
contact an authorised Komatsu dealer.

PRECAUTIONS FOR USING LOAD AND CARRY METHOD 0.

When traveling continuously with load and carry operations, choose the correct tires to match the operating condi-
tions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged, so con-
tact your Komatsu distributor or tire dealer when selecting tires.

3-110
OPERATION TRANSPORTATION PROCEDURE

TRANSPORTATION 0.
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.

TRANSPORTATION PROCEDURE 0.
As a basic rule, always transport the machine on a trailer.
When selecting the trailer, see the weights and dimensions given in Section “TECHNICAL DATA (5-2)“.
Note that the specifications for the weights and dimensions for transportation differ according to the type of tires
and type of bucket.

LOADING, UNLOADING WORK WITH TRAILERS 0.

WARNING
When loading or unloading the machine, run the engine at low speed, travel at low speed, and operate
slowly.
When loading or unloading the machine, stop the trailer on firm level ground.
In addition, keep well away from the road shoulder.
Use ramps of ample width, length, thickness, and strength, and install them securely at an angle of
less than 15°.
When using an embankment, compact the fill soil thoroughly and make sure that the slope face does
not collapse.
Remove the mud stuck to the undercarriage to prevent the machine from slipping to the side on the
ramps.
In addition, remove any water, snow, ice, grease, or oil from the ramps.
Never change direction on the ramps. There is danger that the machine may tip over.
If it is necessary to change direction, return to the ground surface or the trailer platform, correct the
direction, and start again.
The position of the center of gravity of the machine will change suddenly at the connection of the
ramp and trailer, and there is danger of the machine losing its balance. Always drive slowly over this
point.

When loading or unloading, always use ramps or a platform and carry out the operation as follows.

LOADING 0.
1. Perform loading and unloading 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.
Be sure that the two sides are at the same height as one
Ramp
another.
Make the angle of the ramps a maximum of 15°.
Set the distance between the ramps to match the center of
the tires. Blocks
If the lamp sags appreciably, reinforce it with blocks, etc. Distance
Block
3. Determine the direction of the ramp, then slowly load the between ramps
machine.
4. Load the machine correctly in the specified position on the
trailer.

3-111
TRANSPORTATION PROCEDURE OPERATION

SECURING MACHINE 0.
Load the machine on to a trailer as follows.
1. Lower the work equipment slowly.
2. Apply the safety lock lever to lock work equipment control
levers securely.
3. Turn the starting switch to the OFF position to stop the
engine, and pull out the starting switch key. Free
4. Lock front frame and rear frame with safety bar.
5. Put blocks in front and behind the wheels, and secure the
machine with chains or wire rope to prevent the machine Lock
from moving during transportation.
In paticular, fix the machine securely to prevent it from slip-
ping sideways.
6. Always retract the car radio (option) antenna fully.

Free
Lock

UNLOADING 0.
1. Perform loading and unloading 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.
Be sure that the two sides are at the same height as one
Ramp
another.
Make the angle of the ramps a maximum of 15°.
Set the distance between the ramps to match the center of
the tires. Blocks
If the lamp sags appreciably, reinforce it with blocks, etc. Distance
Block
between ramps
3. Remove the chains or wire rope holding the machine.
4. Start the engine.
Warm the engine up fully.
5. Set the safety lock lever to the FREE position.
6. Determine the direction of the ramps, then drive the
machine slowly down the ramps to unload the machine.

Free

Lock

3-112
OPERATION LIFTING MACHINE

LIFTING MACHINE 0.
WARNING
When lifting the machine,if the wire rope is not fitted correctly the machine may fall and cause serious
injury or even death. Raise the machine 100 to 200 mm from the ground, check that the machine is
horizontal and that there is no slack in the wire rope, then continue to lift the machine.
Before lifting the machine, always stop the engine and lock the brakes. Lock front frame and rear
frame with safety bar.
Lifting operations using a crane must be carried out by a qualified operator.
Never raise the machine with any worker on it.
Always make sure that the wire rope used for lifting the machine is of ample strength for the weight of
the machine.
Never try to lift the machine at any position or in any posture other than the posture specified.
Never go under the machine when it is raised.

CAUTION
When the machine is raised, check that there is no leakage of oil from the hydraulic circuits of the
machine.
When carrying out the lifting operation, please contact your Komatsu distributor.

NOTICE
The lifting procedure applies to machines with standard specifications.
The method of lifting differs according to the attachments and options actually installed. In such cases,
please contact your Komatsu distributor for information.

For details of the weight, see “WEIGHT TABLE (3-114)“

3-113
LIFTING MACHINE OPERATION

LOCATION OF LIFTING POSITION MARK 0.

Lifting position mark

WEIGHT TABLE 0.

Machine Front Rear Center of gravity

weight wheel load wheel load (from front axle)

WA380-5H
Standard specification 16,150 kg 7,785 kg 8,365 kg 1,690mm
machine

3-114
OPERATION LIFTING MACHINE

LIFTING PROCEDURE 0.

CAUTION
When the machine is raised, check that there is no leakage of oil from the hydraulic circuits of the
machine.
When carrying out the lifting operation, please contact your Komatsu distributor.

Lifting work can be carried out only for machines with lifting marks. Before starting the lifting operation, stop the
machine in a horizontal place and do as follows.
1. Start the engine, make sure that the machine is horizontal,
then set the work equipment to the travel posture.
F o r d e ta i l s , s e e “ P R E PA R AT I O N S F O R M O V I N G
MACHINE (3-84)“.

2. Move the work equipment safety lock lever to the LOCK

position.

3. Stop the engine,check that the area around the operator‘s

compartment is safe, then lock with the safety bar so that
the front frame and rear frame do not articulate.

4. Fit the lifting equipment to the lifting hooks (marked by the

lifting mark) at the front of the front frame and the rear of the
rear frame.
For machines equipped with a rear full fender, remove the
rear full fender before carrying out out the operation.
5. When the machine leaves the ground, stop for a moment
and wait for the machine to stabilize, then continue the lift-
ing operation slowly.

3-115
LOW TEMPERATURE OPERATION

COLD WEATHER OPERATION 0.

LOW TEMPERATURE 0.
If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as fol-
lows.

FUEL AND LUBRICANTS 0.

Change to fuel and oil with low viscosity for all components. For details of the specified visicosity, see “LUBRI-
CANTS AND OPERATING MEANS (4-9)“.
For the specified viscosity of hydraulic oil, refer to the section of “RECOMMENDED OIL (3-118)“ in the chapter,
Engine Warming-up Run.

COOLANT 0.

WARNING
Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your
eyes or on your skin, wash it off with large quantities of fresh water and see a doctor at once.
Antifreeze is toxic. Be extremely careful when handling it. When replacing coolant containing anti-
freeze or when handling coolant when repairing the radiator, contact your Komatsu distributor or ask
your local antifreeze dealer. Be careful not to let the water flow into drainage ditches or spray on to
the ground surface.
Antifreeze is flammable, so do not bring any flame close. Do not smoke when handling antifreeze.

NOTICE
Never use methanol, ethanol or propanol based antifreeze.
Absolutely avoid using any water leak preventing agent irrespective of weather it is used indepen-
dently or mixed with an antifreeze.
Do not mix one antifreeze with a different brand.

For details of the antifreeze mixture when changing the coolant, see “CLEAN INSIDE OF COOLING SYSTEM (4-
21)“.
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the stan-
dard requirements as shown below. With permanent antifreeze, no change of coolant is required for a year. If it is
doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for infor-
mation.
Standard requirements for permanent antifreeze
SAE J1034
FEDERAL STANDARD O-A-548D

REMARK
In areas where permanent antifreeze is not available, it is possible to use antifreeze whose main compo-
nent is ethylene glycol and does not contain any corrosion inhibitor. (Such antifreeze can be used for the
winter season only.) However, in such a case, the cooling water must be changed twice a year (spring and
fall), so use permanent antifreeze as far as possible.

3-116
OPERATION AFTER COMPLETION OF WORK

BATTERY 0.

WARNING
The battery generates flammable gas, so do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts
of water, and consult a doctor.
Battery electrolyte dissolves paint. If it gets on to the bodywork, wash it off immediately with water.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source. There is danger that the battery may explode.

When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low,
the battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%, and insulate it
against cold temperature so that the machine can be started easily the next morning.

REMARK
Measure the specific gravity and calculate the rate of charge from the following conversion table.

Temperature
(°C)
20 0 -10 -20
Charging
Rate(%)

100 1.28 1.29 1.30 1.31

90 1.26 1.27 1.28 1.29

80 1.24 1.25 1.26 1.27

75 1.23 1.24 1.25 1.26

As the battery capacity drops markedly in low temperatures, cover the battery or remove it from the machine,
keep it in a warm place, and install it again the next morning.
If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add the water
after the day’s work so as to prevent fluid in the battery from freezing in the night.

AFTER COMPLETION OF WORK 0.

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, always observe the following precautions.
Mud and water on the machine body should be completely removed. This is to prevent damage to the seal
caused by mud or dirt getting inside the seal with frozen drops of water.
Park the machine on hard, dry ground.
If this is impossible, park the machine on wooden boards.
The boards help protect the tracks from being frozen in soil and the machine can start next morning.
Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.

AFTER COLD WEATHER 0.

When season changes and the weather becomes warmer, do as follows.
Replace the fuel and oil for all parts with oil of the viscosity specified.
For details, see “LUBRICANTS AND OPERATING MEANS (4-9)“.
If for any reason permanent antifreeze cannot be used, and an ethyl glycol base antifreeze (winter, one season
type) is used instead, or if no antifreeze is used, drain the cooling system completely, then clean out the inside
of the cooling system thoroughly, and fill with fresh soft water.

3-117
WARMING-UP OF STEERING HYDRAULIC OPERATION

WARMING-UP OF STEERING HYDRAULIC 0.

WARNING
If the steering wheel is operated and stopped while the oil
temperature is low, there may be a time lag before the Free
machine stops turninig. Lock
In this case, use the safety bar to ensure safety, and per-
form the warm-up operation in a wide place.
Do not load up the hydraulic oil in the circuit continuously
for more than 5 seconds.

When the temperature is low, do not start the operation of the machine immediately after starting the engine.

Warming up steering hydraulic circuit

Slowly operate the steering wheel to the left and right to warm up the oil in the steering valve. (Repeat this opera-
tion for about 10 minutes to warm up the oil.)

NOTICE
Operate the steering wheel a little and stop in that position. Then, confirm that the machine is being
steered by an angle eqivalent to the amount that the steering wheel is operated

RECOMMENDED OIL 0.
Change oil according to the following table, depending on an ambient temperature.

KIND OF
RESERVOIR AMBIENT TEMPERATURE
FLUID

-22 -4 14 32 50 68 86 104 122°F

30 -20 -10 0 10 20 30 40 50°C

SAE 10WCD

Hydraulic
Engine oil
system
SAE 5W-20CD

SAE 5W-30CD

If SAE5W-20CD is used in the cold season, replace it with SAE10WCD after the cold season is over.

3-118
OPERATION BEFORE STORAGE

LONG-TERM STORAGE 0.
BEFORE STORAGE 0.
When putting the machine in storage for a long time, do as follows.
Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select
level ground and cover the machine with a sheet.
Completely fill the fuel tank, lubricate and change the oil before storage.
Apply a thin coat of grease to the metal surface of the hydraulic piston rods.
Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it sepa-
rately.
If the ambient temperature is expected to drop below 0°C, add antifreeze to the cooling water.
Since Komatsu genuine super coolant (AF-ACL) is added normally, it may be unnecessary to change when the
temperature is above -10°C. If it drops below - 10°C, see “CLEAN INSIDE OF COOLING SYSTEM (4-21)“ for
the adjustment of concentration ratio.
Lock each control lever and pedal with the lock lever and pedal lock.

DURING STORAGE 0.
WARNING
If it is unavoidably necessary to carry out the rust-preventive operation while the machine is indoors,
open the doors and windows to improve ventilation and prevent gas poisoning.

During storage, always operate the machine once a month so that a new film of oil will be coated over movable
parts and component surfaces. At the same time, also charge the battery.
When operating the work equipment, wipe off all the grease from the hydraulic cylinder rod.
If the machine is equipped with an airconditioner, operate it for 3 to 5 minutes once a month to lubricate each
portion of its compressor. Be sure to idle the engine at low speed for this purpose. Also, check the quantity of
refrigerant twice a year.

AFTER STORAGE 0.
NOTICE
If the machine is to be used when the monthly rust prevention operation has not been carried out, please
contact your Komatsu distributor.

When using the machine after long-term storage, do as follows before using it.
Wipe off the grease from the hydraulic cylinder rods.
Add oil and grease to all places.
When a machine is stored for a long period, moisture in the air will get into the oil. Check the oil before and
after starting the engine. If there is water in the oil, change the oil.

3-119
WHEN MACHINE RUNS OUT OF FUEL OPERATION

TROUBLESHOOTING 0.
WHEN MACHINE RUNS OUT OF FUEL 0.
In case that the machine has run out of fuel, start the engine again only after refilling fuel, filling the water separator
and fuel filter cartridge with clean fuel and bleeding air from the fuel system.
Always watch the fuel level and be careful not to run out of fuel.
If the engine has stopped because of lack of fuel, it is necessary to use the priming pump to bleed the air com-
pletely from the fuel circuit.

PROCEDURE FOR BLEEDING AIR 0.

CAUTION
Be careful when unscrewing the air bleeding plug on the fuel filter head. Oil may spurt out due to the
residual pressure inside the tank.

1. Remove water separator (1), fill the inside of the strainer

with clean fuel, taking care not to let dirt or dust get in, then
install it again.
2. Remove fuel filter cartridge (2), fill the inside of the filter with
clean fuel, taking care not to let dirt or dust get in, then
install it again.
Add fuel from small hole (A) (dirty side) at eight places. Do
not add fuel from hole (B) (clean side) at the center.
If clean fuel is not available, go on to Step 3.
3. Loosen air bleed plug (3) at the fuel filter head.
4. Bleed air with priming pump (4) and check that air bubbles
come out of air bleeding plug (3), followed by fuel.
5. Tighten air bleed plug (3).
Tightening torque: 7.8 to 9.8 N·m (0.8 to 1 kgf·m)

6. Turn the key in the starting switch to the START position and start the engine.
When doing this, do not crank the starting motor continuously for more than 20 seconds. If the engine does not
start, wait for at least 2 minutes, then try again. Perform this operation a maximum of 4 times.
7. If the engine does not start, repeat the operation from Step 3.

3-120
OPERATION TOWING THE MACHINE

TOWING THE MACHINE 0.

WARNING
Check that the wire rope is of ample strength for the weight of the machine being towed.
Do not apply a load to the wire rope suddenly.
If there is a failure in the brake line, the brakes cannot be used, so be extremely careful when towing.

NOTICE
Towing is for moving the machine to a place where inspection and maintenance can be carried out, and
not for moving it long distances.
The machine must not be towed for long distances.
For details of the procedure for towing a machine when it has broken down, please contact your
Komatsu distributor.

This machine must not be towed except in emergencies. When towing the machine, take the following precau-
tions.
When releasing the brakes, put blocks under the wheels to prevent the machine from moving. If the wheels are
not blocked, the machine may suddenly move.
When towing a machine, tow it at a low speed of less than 2 km/h, and for a distance of a few meters to a place
where repairs can be carried out. The machine should be towed only in emergencies. If the machine must be
moved long distances, use a transporter.
To protect the operator if the towing rope or bar should break, install a protector plate to the machine being
towed.
If it is impossible to operate the steering and brakes of the machine being towed, do not let anyone ride on the
machine.
Check that the tow rope or bar is of ample strength for the weight of the machine being towed. If the machine
being towed must travel through mud or up hills, use a tow rope or bar of a strength of at least 1.5 times the
weight of the machine being towed.
Keep the angle of the tow rope as small as possible. Keep the angle between the center lines of the two
machines to within 30 degrees.
If the machine is moved suddenly, the tow rope or bar will be subjected to an excessive load, and it may break.
Start the machine gradually and travel at a constant speed.
The towing machine should normally be of the same class as the machine being towed. Check that the towing
machine has ample braking power, weight, and rimpull to allow it to control both machine on slopes or on the
tow road.
When towing a machine downhill, use a larger machine for towing to provide ample rimpull and braking power,
or connect another machine to the rear of the machine being towed. In this way it is possible to prevent the
machine from losing control and turning over.
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.

WHEN ENGINE CAN BE USED 0.

If the transmission and steering wheel can be operated, and the engine is running,it is possible to tow the
machine out of mud or to move it for a short distance to the edge of the road.
The operator should sit on the machine being towed and operate the steering in the direction that the machine
is towed.

3-121
TOWING THE MACHINE OPERATION

WHEN ENGINE CANNOT BE USED 0.

When towing a machine with the engine stopped, use the following procedure.
1. The transmission oil does not lubricate the system, so remove the front and rear drive shafts. If necessary,
block the tires to prevent the machine from moving.
2. The steering cannot be operated, so remove the steering cylinder.
Even if the brakes are in good condition, the brakes can only be used a limited number of times. There is no
change in the operating force for the brake pedal, but the braking force is reduced each time the pedal is
depressed.
3. Connect the towing equipment securely. When carrying out towing operations, use two machines of at least
the same class as the machine being towed. Connect one machine each to the front and rear of the machine
being towed, then remove the blocks from the tires and tow the machine.
4. Parking brake
The parking brake cannont be turned OFF. To release the parking brake, do as follows.

RELEASING PARKING BRAKE 0.

WARNING
When releasing the parking brake, stop the machine on level ground and check that the surrounding
area is safe. If it is necessary to release the brake on a slope in an emergency, block the tires before
starting the operation.
If the parking brake is released, the brake cannot be used, so check the safety carefully when moving
the machine.

If the engine will not run for some reason, use the following methods to release the parking brake and tow the
machine.

METHOD OF RELEASING PARKING BRAKE WITH EMERGENCY PARKING BRAKE RELEASE

VALVE 0.

CAUTION
When the parking brake switch is at the OFF position and the emergency parking brake release valve is
opened, the parking brake is released immediately.
In this condition, even if you feel danger and try to stop the machine, the parking brake will not be applied
immediately even if you close the emergency parking brake release valve.

If the pressure in the brake accumulator is high, do as follows.

1. Turn the starting switch to the OFF position.

3-122
OPERATION TOWING THE MACHINE

2. Loosen relief valve lock nut (1) by turning it counterclock-

wise, and turn grip (2) likewise to relieve the valve.

REMARK
The relief valve is located on the left front portion inside
the rear frame and secured to the accumulator mounting
bracket.

3. Turn the starting switch ON.

4. Move the parking brake switch to the ON (a) position (actu-

ated), then move it to the OFF (b) position (released).
The parking brake is released.

5. To restore the function of the parking brake, turn grip (2) of

the release valve clockwise to close the release valve, then
turn locknut (1) clockwise to lock it.
Tightening torque
Grip (2): 25 ± 5 N·m (2.5 ± 0.5 kgf·m)
Locknut (1): 20 ± 5 N·m (2.0 ± 0.5 kgf·m)
6. Move the parking brake switch to the ON (a) position. The
parking brake is applied.
To release the parking brake again, repeat the procedure in
Steps 1 to 4.

REMARK
If the brake accumulator pressure is low, the parking brake warning lamp may not go out, or the alarm
buzzer may sound continuously. If this happens, go to the following section “METHOD OF RELEASING
MECHANICALLY (3-124)“ and release the brake.

3-123
TOWING THE MACHINE OPERATION

METHOD OF RELEASING MECHANICALLY 0.

1. Remove plugs (1) and (2) at the front of the transmission
case.
2. Of the bolts installing the parking brake chamber, 4 bolts (3)
have a high (3 mm) mounting seat. Remove 2 of bolts (3).
3. Screw bolts (3) into the holes from which plugs (1) and (2)
were removed and tighten uniformly until they stop.
4. This releases the parking brake.

Therad hole M12

for releasing

Plug mounting hole

Taper mounting hole

EMERGENCY TRAVEL OPERATION 0.

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.

3-124
OPERATION BATTERY IS DISCHARGED

BATTERY IS DISCHARGED 0.

WARNING When removing, disconnect the cable

from the ground terminal first
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 haz-
ard of explosion. Do not bring lighted cigarettes near
the battery, or do anything that will cause sparks.
Battery electrolyte is dilute sulphuric acid, and it will
attack your clothes and skin. If it gets on your clothes
or on your skin, wash it immediately off with large
amounts of water. If it gets in your eyes, wash it out
with fresh water, and consult a doctor.
When handling batteries, always wear protective gog-
gles and rubber gloves. When installing, connect the cable
When removing the battery, first disconnect the cable to the positive (+) terminal first
from the ground (normally the negative (-) terminal).
When installing, install the positive (+) terminal first.
If a tool touches the positive terminal and the chassis,
there is danger that it will cause a spark, so be
extremely careful.
If the terminals are loose, there is danger that the
defective contact may generate sparks that will cause
an explosion.
When removing or installing the terminals, check
which is the positive (+) terminal and which is the neg-
ative (-) terminal.
Green rust around the terminals is a cause of self-dis-
charge of the battery. Polish the terminals with sand-
paper. After removing the rust, coat the terminals
thinly with grease before installing.

REMOVAL AND INSTALLATION OF BATTERY 0.

1. Before removing battery, remove the ground cable (normally connected to the negetive (-) terminal). If any tool
touches between the positive terminal and the chassis, there is danger of sparks being generated. Loosen the
terminal and remove the wires from the battery.
2. After installing the battery, fix it with the battery fitting securely.
Tightening torque: 2 to 2.9 N·m (0.2 to 0.3 kgf·m)
3. When install the battery, connect the ground cable last.
Insert the hole of the terminal on the battery and tighten the nut.
Tightening torque: 5.9 to 9.8N·m (0.6 to 1.0kgf·m)

REMARK
The batteries are on both sides at the rear of the machine. The battery used for the ground is on the left
side of the machine.

3-125
BATTERY IS DISCHARGED OPERATION

PRECAUTIONS FOR CHARGING BATTERY 0.

When charging the battery, if the battery is not handled cor-
rectly, there is danger that the battery may explode. Always
follow the instructions in “BATTERY (3-117)“ and the instruc-
tion 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. This may cause an
explosion. Always check the battery electrolyte level period-
ically and add distilled water to bring the electrolyte level to
the UPPER LEVEL line.
Set the voltage of the charger to match the voltage of the
battery to be charged. If the voltage is not selected correctly,
the charger may overheat and cause an explosion.
Connect the positive (+) charger clip of the charger to the
positive (+) terminal of the battery, then connect the nega-
tive (-) charger clip of the charger to the negative (-) terminal
of the battery. Be sure to fix the clips securely.
Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging, set
it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire
and explode.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery electrolyte and cause the battery to explode.

STARTING ENGINE WITH BOOSTER CABLE 0.

When starting the engine with a booster cable, do as follows:

PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE 0.

WARNING
When connecting the cables, never contact the posi-
tive (+) and negative (-) terminals.
When starting the engine with a booster cable, always
wear safety glasses and rubber gloves.
Be careful not to let the normal machine and problem
machine contact each other. This prevents sparks
from generating near the battery which could ignite
the hydrogen gas given off by the battery.
Make sure that there is no mistake in the booster
cable connections. The final connection is to the
engine block of the problem machine, but sparks will
be generated when this is done, so connect to a place
as far as possible from the battery.
When disconnecting the booster cable, take care not
to bring the clips in contact with each other or with the
machine body.

NOTICE
The size of the booster cable and clip should be suitable for the battery size.
The battery of the normal machine must be the same capacity as that of the engine to be started.
Check the cables and clips for damage or corrosion.
Make sure that the cables and clips are firmly connected.
Check that the safety lock levers and parking brake levers of both machines are in the LOCK position.
Check that each lever is in the NEUTRAL position.

3-126
OPERATION BATTERY IS DISCHARGED

CONNECTING THE BOOSTER CABLE 0.

Keep the starting switch of the normal machine and problem machine are both at 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 (+) ter-
minal of the problem machine.
2. Connect the other clip of booster cable (A) to the positive
(+) terminal of the normal machine.
3. Connect one clip of booster cable (B) to the negative (-) ter-
minal of the normal machine.
4. Connect the other clip of booster cable (B) to the engine
block of the problem machine. Battery of the Battery of the
normal machine problem machine
Engine block of
the problem machine

STARTING ENGINE 0.

CAUTION
Always check that the safety lock lever is set to the LOCK position, regardless of whether the machine is
working normally or has failed. Check also that all the control levers are at the HOLD or neutral position.

1. Make sure the clips are firmly connected to the battery terminals.
2. Start the engine of the normal machine and keep it to run at high idling speed.
3. Turn the starting switch of the problem machine to the START position and start the engine.
If the engine doesn’t start at first, wait for at least 2 minutes before trying again.

DISCONNECTING THE BOOSTER CABLE 0.

After the engine has started, disconnect the booster cables in the reverse of the order in which they were con-
nected.
1. Remove one clip of booster cable (B) from the engine block
of the problem machine.
2. Remove the other clip of booster cable (B) from the nega-
tive (-) terminal of the normal machine.
3. Remove one clip of booster cable (A) from the positive (+)
terminal of the normal machine.
4. Remove the other clip of booster cable (A) from the positive
(+) terminal of the problem machine. Battery of the Battery of the
normal machine problem machine
Engine block of
the problem machine

3-127
OTHER TROUBLE OPERATION

OTHER TROUBLE 0.
ELECTRICAL SYSTEM 0.
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for
repairs.

Problem Main causes Remedy

Lamp does not glow brightly even •Defective wiring (•Check, repair loose terminals,
when the engine runs at high disconnections)
speed •Defective adjustment of belt ten- •Adjust alternator belt tension
Lamp flickers while engine is run- sion For details, see EVERY 250
ning HOURS SERVICE

Even when the engine is rotating, •Defective alternator (•Replace)

the charge caution pilot lamp does •Defective wiring (•Check, repair)
not go out •Defective adjustment of alternator •Adjust alternator belt tension
belt tension For details, see EVERY 250
HOURS SERVICE

Abnormal noise is generated from •Defective alternator (•Replace)

alternator

Starting motor does not turn when •Defective wiring (•Check, repair)
starting switch is turned to ON •Insufficient battery charge •Charge

Pinion of starting motor keeps •Insufficient battery charge •Charge

going in and out

Starting motor turns engine slug- •Insufficient battery charge •Charge

gishly •Defective starting motor (•Replace)

Starting motor disengages before •Defective wiring (•Check, repair)

engine starts •Insufficient battery charge •Charge

Preheating pilot lamp does not light (•Check, repair)

•Defective wiring
up (•Replace)
•Defective glow relay, glow control-
ler, water temperature sensor
•Defective preheating pilot lamp
(•Replace)

Even when engine is stopped, •Defective wiring (•Check, repair)

charge caution pilot lamp does not •Defective monitor (•Replace)
light up (starting switch at ON posi-
tion)

3-128
OPERATION OTHER TROUBLE

CHASSIS 0.
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for
repairs.

Problem Main causes Remedy

Transmission

Engine is running but machine •Parking brake is applied •Release parking brake
does not move •Directional lever is not shifted •Shift lever properly
properly
•Lack of oil in transmission case •Add oil to specified level.
See WHEN REQUIRED

Even when engine is run at full •Lack of oil in transmission case •Add oil to specified level.
throttle, machine only move slowly See WHEN REQUIRED
and lacks power •Screen is clogged (•Disassemble, clean)

Oil overheats •Too much oil or too little oil •Add or drain oil to specified level.
See WHEN REQUIRED
•Machine is not traveling in correct •Place in correct speed range
speed range
•Torque converter is stalled for •Reduce stall time
long periods
•Engine is overheating (•Check engine)

Noise generated •Lack of oil •Add oil to specified level.

See WHEN REQUIRED

Axle
Noise generated •Lack of oil •Add oil to specified level.
See WHEN REQUIRED
•Improper oil used (for machines •Change to specified oil
with anti-slip differential)

Brake

Brake is not applied when pedal is •Disc has reached wear limit (•Replace disc)
depressed •Defective hydraulic system
· Lack of oil •Add oil to specified level.
See EVERY 100 HOURS
•Air in brake line •Bleed air
See WHEN REQUIRED

•Vent hole of brake valve is

Brake drags or remains applied •Clean
clogged

Brakes squeal •Disc is worn (•Replace disc)

•Large amount of water in axle oil •Change axle oil
•Deteriorated axle oil due to over- •Change axle oil
use of brake

3-129
OTHER TROUBLE OPERATION

Problem Main causes Remedy

Steering

Steering wheel is heavy •Defective hydraulic system

· 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
•Defective hydraulic system
· Lack of oil •Add oil to specified level.
See EVERY 100 HOURS
SERVICE

Parking brake

Braking effect is poor •Disc is worn (•Replace disc)

Brake drags or remains applied •Lack of oil in transmission case •Add oil to specified level.
•Screen is clogged See WHEN REQUIRED
(•Disassemble and clean)

Hydraulic system

Lack of lifting power for bucket •Lack of oil •Add oil to specified level.
See EVERY 100 HOURS
SERVICE
Bucket takes time to rise •Clogged hydraulic tank filter •Replace filter.
See EVERY 2000 HOURS
SERVICE

Excessive bubbles in oil •Low quality oil being used •Replace with good quality oil
•Oil level is low •Add oil to specified level.
See EVERY 100 HOURS
SERVICE
•Air in oil line •Bleed air.
See EVERY 2000 HOURS
SERVICE

Hydraulic pressure is low •Oil level is low and pump is suck- •Add oil to specified level.
ing in air See EVERY 100 HOURS
SERVICE
Then bleed air.
See EVERY 2000 HOURS
SERVICE

Movement of cylinder is irregular •Oil level is low •Add oil to specified level.
See EVERY 100 HOURS
SERVICE

3-130
OPERATION OTHER TROUBLE

ENGINE 0.
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for
repairs.

Problem Main causes Remedy

Engine oil pressure caution pilot •Low engine oil pan oil level •Add oil to specified level, see
lamp lights up (sucking in air) CHECK BEFORE STARTING
•Clogged oil filter cartridge •Replace cartridge, see EVERY
500 HOURS SERVICE
•Defective tightening of oil pipe (•Check, repair)
joint, oil leakage from damaged
part
•Defective monitor (•Replace)

Steam is emitted from top part of •Low cooling water level, water •Check, add cooling water,
radiator (pressure valve) leakage repair, see WHEN REQUIRED
•Defective fan pump or motor (•Check, repair)
Water temperature gauge is in red •Dirt or scale accumulated in cool- •Change cooling water, clean
range ing system inside of cooling system, see
Coolant temperature monitor lights WHEN REQUIRED
up •Clogged radiator fin or damaged •Clean or repair, see WHEN
fin REQUIRED
•Defective thermostat (•Replace thermostat)
•Defective thermostat seal (•Replace thermostat seal)
•Loose radiator filler cap (high alti- •Tighten cap or replace packing
tude operation)
•Defective monitor (•Replace)

Water temperature gauge is in •Defective thermostat (•Replace thermostat)

white range on left •Defective monitor (•Replace)
•Lack of fuel •Add fuel, see CHECK BEFORE
Engine does not start when start-
STARTING
ing motor is turned
•Air in fuel system •Repair place where air is sucked
in
•No fuel in fuel filter •Fuel filter with fuel. See EVERY
500 HOURS SERVICE
•Defective injection pump or injec- (•Replace pump or injector)
tor
•Starting motor cranks engine too •See ELECTRICAL SYSTEM
slowly
•Starting motor does not turn •See ELECTRICAL SYSTEM
•Preheating pilot lamp does not •See ELECTRICAL SYSTEM
light up
•Defective valve clearance (•Adjust valve clearance)
(Defective compression)

Exhaust gas is white or blue •Too much oil in oil pan •Add oil to specified level, see
CHECK BEFORE STARTING
•Improper fuel •Change to specified fuel

Exhaust gas occasionally turns

•Clogged air cleaner element •Clean or replace, see WHEN
black
REQUIRED
•Defective injector (•Replace injector)
•Defective compression (•See defective compression
above)
•Defective turbocharger (•Clean or replace turbocharger)

3-131
OTHER TROUBLE OPERATION

Problem Main causes Remedy

Combustion noise occasionally (•Replace nozzle)

•Defective nozzle
makes breathing sound

Abnormal noise generated (com- •Low grade fuel being used •Change to specified fuel
bustion or mechanical) •Overheating •Refer to “Water temperature
gauge is in red range“ as above
•Damage inside muffler (•Replace muffler)
•Excessive valve clearance (•Adjust valve clearance)

3-132
MAINTENANCE
24

WARNING
Please read and make sure that you understand the safety
volume before reading this section.
 MAINTENANCE

4-2
MAINTENANCE GUIDES TO MAINTENANCE

GUIDES TO MAINTENANCE 0.
Do not carry out any inspection and maintenance operation that is not found in this manual.

CHECK SERVICE METER: 0.

Check the service meter reading every day to see if the time has come for any necessary maintenance to be car-
ried out.

KOMATSU GENUINE REPLACEMENT PARTS: 0.

Use Komatsu genuine parts specified in the Parts Book as replacement parts.

KOMATSU GENUINE OILS: 0.

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem-
perature.

ALWAYS USE CLEAN WASHER FLUID: 0.

Use automobile window washer fluid, and be careful not to let any dirt get into it.

ALWAYS USE CLEAN OIL AND GREASE: 0.

Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from
oil and grease.

CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS: 0.

After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If
large quantities of metal particles or foreign materials are found, always report to the person in charge, and carry
out suitable action.

FUEL STRAINER: 0.
If your machine is equipped with a fuel strainer, do not remove it while fueling.

WELDING INSTRUCTIONS: 0.
Turn off the engine starting switch.
Do not apply more than 200V continuously.
Connect grounding cable within 1m from the area to be welded. If grounding cable is connected near instru-
ments, connectors, etc., the instruments may have troubles.
Avoid seals or bearings from being between the area to be welded and the position of grounding point.
Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.

DO NOT DROP THINGS INSIDE MACHINE: 0.

When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop
nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it will cause damage and malfunction of the machine, and will
lead to failure. If you drop anything inside the machine, always remove it immediately.
Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.

DUSTY WORKSITES: 0.
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.
Clean and replace the fuel filter frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting
into the oil.

4-3
GUIDES TO MAINTENANCE MAINTENANCE

AVOID MIXING OIL: 0.

Never mix different kinds of oil. If a different type of oil has to be added, drain the old oil and replace all the oil with
the new type of oil.

LOCKING INSPECTION COVERS: 0.

Lock inspection cover in position securely with a lock bar. If inspection or maintenance is carried out with the
inspection cover open and not locked in position, there is a hazard that it may be suddenly blown shut by the wind
and cause injury to the worker.

BLEEDING AIR FROM HYDRAULIC CIRCUIT: 0.

If the hydraulic oil equipments have been repaired or replaced and if the hydraulic hoses, pipes, etc. have been
disconnected, it is necessary to bleed air in the circuit. See “CHANGE OIL IN HYDRAULIC TANK, REPLACE
HYDRAULIC FILTER ELEMENT ( 4-48 )“.

PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES: 0.

When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace with new parts.
When doing this, be careful not to forget to assemble the O-rings and gaskets.
When installing the hoses, do not twist them or bend them into loops with a small radius.
This will cause damage to the hose and markedly reduce its service life.

CHECKS AFTER INSPECTION AND MAINTENANCE: 0.

If you forget to carry out the checks after inspection and maintenance, unexpected problems may occur, and this
may lead to serious injury or property damage. Always do as follows.
Checks after operation (with engine stopped)
Have any inspection and maintenance points been forgotten?
Have all inspection and maintenance items been carried out correctly?
Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside machine and get caught in the lever linkage mechanism.
Is there any leakage of water or oil? Have all the bolts been tightened?
Check when the engine is running
See “TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING ( 2-25 )“ in the section on
safety for checking when the engine is running. Pay enough attention for safety.
Check if the inspected and maintenance area is normally operated.
Increase the engine speed to check for the leak of fuel and oil.

4-4
MAINTENANCE OUTLINES OF SERVICE

OUTLINES OF SERVICE 0.
OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 0.
OIL 0.
Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pres-
sure), and is deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Man-
ual.
Even if the oil is not dirty, always change the oil after the specified interval.
Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of problems with machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.

FUEL 0.
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15°C).
It is necessary to change for the fuel that is suitable for the temperature.
To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel
tank after completing the day's work.
Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water
from the fuel tank.
If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

COOLANT 0.
River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the engine
and radiator, and this will cause defective heat exchange and overheating.
Do not use water that is not suitable for drinking.
When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.
Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped.
This anti-freeze is effective in preventing corrosion of the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is even in
hot areas.
Anti-freeze is flammable, so be extremely careful not to expose it to flame or fire.
The proportion of anti-freeze to water differs according to the ambient temperature.
For details of the mixing proportions, see “CLEAN INSIDE OF COOLING SYSTEM ( 4-21 )“.
If the engine overheats, wait for the engine to cool before adding coolant.
If the coolant level is low, it will cause overheating and will also cause problems with corrosion from the air in
the coolant.

GREASE 0.
Grease is used to prevent twisting and noise at the joints.
The nipples not included in the maintenance section are nipples for overhaul, so they do not need grease.
If any part becomes stiff after being used for long time, add grease.
Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause
wear of the rotating parts.

4-5
OUTLINES OF SERVICE MAINTENANCE

CARRYING OUT KOWA (Komatsu Oil Wear Analysis) 0.

KOWA is a maintenance service that makes it possible to prevent machine failures and down-time. With KOWA,
the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and
other abnormalities.
Periodic use of KOWA makes the following possible:
It enables abnormalities to be detected early, leading to reduction of repair costs and machine downtime.
It enables repair schedules to be planned, leading to improved machine availability.

KOWA analysis items 0.

Analysis of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to
measure the density of metal wear particles in the oil.

Measurement of particle quantity

This uses a PQI (Particle Quantifier Index) measurer to
measure the quantity of large iron particles in the oil.

Others
Measurements are made of items such as the ratio of water or fuel in the oil, and the dynamic viscosity.

Oil sampling 0.
Sampling interval
250 hours: Engine
500 hours: Other components
Precautions when sampling
Make sure that the oil is well mixed before sampling.
Carry out sampling regularly at fixed intervals.
Do not carry out 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.

STORING OIL AND FUEL 0.

Keep indoors to prevent any water, dirt, or other impurities from getting in.
When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at
the side. (To prevent moisture from being sucked in)
If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures to protect
them.
To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use
the oldest oil or fuel first).

4-6
MAINTENANCE OUTLINES OF SERVICE

FILTERS 0.
Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
When replacing oil filters, check if any metal particles are affixed to the old filter. If any metal particles are found,
please contact your Komatsu distributor.
When replacing the engine oil filter, fill the new filter with the specified clean oil, then install it.
Do not open packs of spare filters until just before they are to be used.
Always use Komatsu genuine filters.

BIODEGRADABLE HYDRAULIC OIL AND LUBRICANTS 0.

The use of biodegradable hydraulic oils and lubricants - on the basis of synthetic esters - for Komatsu
machines is permitted. For information on the products cleared for use and best suited for your application con-
tact our authorized service workshops.

OUTLINE OF ELECTRIC SYSTEM 0.

It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged.
This will cause electrical leakage and may lead to malfunction of the machine. Do not wash the inside of the
operator’s cab with water. When washing the machine, be careful not to let water get into the electrical compo-
nents.
Service relating to the electric system is check of fan belt tension, check of damage or wear in the fan belt and
check of battery fluid level.
Never install any electric components other than there specified by Komatsu.
External electrical interference may cause malfunction of the control system controller, so before installing a
radio receiver or other wireless equipment, please contact your Komatsu distributor.
When working at the seashore, carefully clean the electric system to prevent corrosion.
The optional power source must never be connected to the fuse, starting switch, or battery relay.

4-7
WEAR PARTS MAINTENANCE

WEAR PARTS 0.
Wear parts such as the filter element, air cleaner element, buckt tooth, etc. are to be replaced at the time of peri-
odic maintenance or before their abrasion limits.
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.

WEAR PARTS LIST 0.

The parts in parentheses are to be replaced at the same time.
*: See Part no. in Parts Book.

Item Part No. Part Name Q’ty Replacement frequency

Engine oil filter * Cartridge 1 EVERY 500 HOURS

Fuel filter * Cartridge 1 EVERY 500 HOURS

Water separator * O-ring 1 -

Transmission oil filter * Cartridge 1 EVERY 1000 HOURS

Transmission strainer * O-ring 1 EVERY 1000 HOURS

Corrosion resistor * Cartridge 1 EVERY 1000 HOURS

Element 1
Hydraulic filter * EVERY 2000 HOURS
(O-ring) j (1)
Hydraulic tank breather * Element 1 EVERY 2000 HOURS

Air cleaner * Element ass’y 1 -

Air conditioner fresh air filter * Element 1 EVERY 2000 HOURS

Center edge 1
Side edge 2
Standard type * (Bolt) (14) -
(Nut) (14)
(Washer) (14)

Center edge 2
Bolt on cut- Side edge 2
ting edge Long life type * (Bolt) (16) -
(Nut) (16)
(Washer) (16)

Edge 7
(Bolt) (14)
Segment type * -
(Nut) (14)
(Washer) (14)

4-8
MAINTENANCE LUBRICANTS AND OPERATING MEANS

LUBRICANTS AND OPERATING MEANS 0.

LUBRICATION CHART 0.

1. Lubrication intervals are based on the service meter reading.

2. Abbreviations:
EO = Engine Oil, G = Lithium Grease No. 2, F = Diesel Fuel, AXO = Axle Oil (AXO 75), HO = Hydraulic Oil.
3. Numbers at the left side of the chart indicate the number of lubrication points. Refer to the above illustration.
4. Items marked * should be performed in the first service for new machines after 250 hour driving.
5. Refer to the operation and maintenance manual for details.

Binding is the maintenance schedule chart in operation and maintenance manual on page 4-15.

4-9
LUBRICANTS AND OPERATING MEANS MAINTENANCE

LUBRICANTS, FUELS AND FILLING CAPACITIES 0.

LUBRICANTS, FUELS AND FILLING CAPACITIES

WA380-5H Lubricants and

Temperature Viscosity
Filling
operating Short term Quality grades capacities
rangese ranges
mediums in litres

EO 1540 A ACEA E5 -15° up to 50° C SAE 15W-40 *)

EO 1030 A or, if not available: -20° up to 40° C SAE 10W-30 37
Engine Engine oill
EO 30 API CE or - 0° up to 40° C SAE 30 (32 **)
EO 10 API CF -4 -20° up to 10° C SAE 10W

ACEA E5
62
Transmission Engine oil EO 10 or, if not available: -30° up to 40° C SAE 10W *)
(54 **)
API CD

HYD 0530 -30° up to 40° C ISO VG46 *)

Hydraulic oil HVLP, HVLP D
HYD 1030 -20° up to 30° C ISO VG68
Hydraulic 186
system ACEA E5 (129**)
or Engine oil EO 10 or, if not available: -30° up to 40° C SAE 10W
API CD

AXO 80 (*3) 80 W
Axle oil Shell: DONAX TD5W-30 ***)
Axles with AXO SAE 5W-30 *)
standard lock ACEA E5
differential or Engine oil EO 30 or, if not available:: 0° up to 30° C SAE 30
ever 38
API CD
(ever 38**)
Shell: DONAX TD5W-30 ***) SAE 5W-30 *)
Axles with
Esso: TORQUE FLUID 56 ****)
limited slip Axle oil (*5) AXO
Mobil: MOBILFLUID 424
differential (*4)
Fuchs: TITAN HYDRA ZF20W-40 SAE 20W-40

ASTM D975 No.1 -30° up to -10° C

ASTM D975 No.2 -10° up to 40° C
Fuel tank Diesel fuel (*2) CFPP class B 0° up to 40° C ----- 300
DIN-EN 590 CFPP class D -10° up to 40° C
CFPP class F -20° up to 40° C

Multi purpose
Grease nippels grease on a MPG-A KP2N-20 ----- NLGI-No. 2 ---
lithium base

Grease nippels
Multi purpose
for central lubri-
grease on a MPG-A KP2N-20 up to -20° C NLGI-No. 2 ---
cation
lithium base
(up to -20° C)

Grease nippels
for central lubri- Grease for cen- -40° up to NLGI-No.
MPG-G ----- ---
cation tral lubrications 100° C 00/000
(below -20° C)

TEXACO: Havoline XLC *) *****)

Tanigawa Oil: NA2001
Cooling system Water AF-NAC CCI: L246 36
TOTAL FINA ELF: GlLACELF CHP SUPRA
Showa: MCR20

* Works filling
** Top-up quantity
*** North American manufacted DONAX TD 20W-40 must not be used.
**** North American manufacted TORQUE FLUID 56 must not be used.
***** Proportion of mixture: 50% coolant : 50% water, Min. freeze proofing: -35°C

4-10
MAINTENANCE LUBRICANTS AND OPERATING MEANS

*1 :ASTM D975 No.1

*2 : Use only diesel fuel.
*3: For the standard differential, except for “AXO80“, the oil for machines equipped with the limited-slip differential
in the table below and E030 can be used. However, in the case of “E030“, depending on conditions such as the
way the brakes are used and the oil temperature, the brakes may squeal just before the machine stops, but
there is no problem with the brake performance or durability.
*4: The letters “ASD“ are stamped on the name plate of machines equipped with the limited-slip differential axle.
*5: For machines equipped with the limited-slip differential axle, select from the oil given in the table below.
Never use any oil except the oil listed in the table below.

Maker Brand Remarks

North American manufactured

SHELL DONAX TD 5W-30
DONAX TD 20W-40 must not be used

North American manufactured must

ESSO TORQUE FLUID 56
not be used

MOBIL MOBILFLUID 424

FUCHS RENOGEAR HYDRA ZF 20W-40

REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan according to every periodic main-
tenance hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.

When starting the engine with an atmospheric temperature of lower than 0°C, be sure to use engine oil
of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C
more or less during the day.

Use API classification CD as engine oil and if API classification CC, reduce the engine oil change inter-
val to half.

There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to
add single grade oil that matches the temperature range in the table.

We recommend Komatsu genuine oil which has been specifically formulated and approved for use in
engine and hydrauric work equipment applications.

Specified capacity: Total amount of oil including oil for components and oil in piping.

Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Insitute

Charge interval of oil in

Fuel sulphur content
engine oil pan

0.5 to 1.0% 1/2 of regular interval

Above 1.0% 1/4 of regular interval

4-11
STANDARD TIGHTENING TORQUES MAINTENANCE

STANDARD TIGHTENING TORQUES 0.

TORQUE LIST

CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to
the tightened parts, and this will cause failure of the machine or problems with operation.
Always pay careful attention when tightening parts.

Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
The tightening torque is determined by the width across the flats of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that
was replaced.

Thread Width Tightening torque

diameter across Target value Service limit
of bolt flats
(a)(mm) (b)(mm) N·m kgf·m N·m kgf·m
6 10 13.2 1.35 11.8-14.7 1.2-1.5
8 13 31 3.2 27-34 2.8-3.5
10 17 66 6.7 59-74 6.0-7.5
12 19 113 11.5 98-123 10.0-12.5
14 22 177 18 157-196 16.0-20.0
16 24 279 28.5 245-309 25.0-31.5
18 27 382 39 343-425 35.0-43.5
20 30 549 56 490-608 50.0-62.0
22 32 745 76 662-829 67.5-84.5
24 36 927 94.5 824-1030 84.0-105.0
27 41 1320 135.0 1180-1470 120.0-150.0
30 46 1720 175.0 1520-1910 155.0-195.0
33 50 2210 225.0 1960-2450 200.0-25.0
36 55 2750 280.0 2450-3040 250.0-310.0
39 60 3280 335.0 2890-3630 295.0-370.0

Apply the following table for Hydraulic Hose.

Width Tightening torque

Nominal - No. of across
Target value Permissible range
threads (a) flats (b)
(mm) N·m kgf·m N·m kgf·m

9/16 -18UNF 19 44 4.5 35 - 63 3.5 - 6.5

11/16 -16UN 22 74 7.5 54 - 93 5.5 - 9.5

13/16 -16UN 27 103 10.5 84 - 132 8.5 - 13.5

1 -14UNS 32 157 16.0 128 - 186 13.0 - 19.0

13/16 -12UN 36 216 22.0 177 - 245 18.0 - 25.0

4-12
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS0.

To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out
periodic maintenance. In addition, to further improve safety, the parts in the safety-critical parts list must also be
replaced at the specified interval. These parts are particularly closely connected to safety and fire prevention, so
please contact your Komatsu distributor to have them replaced.
With these parts, the material changes as time passes, or they easily wear out or deteriorate. However, it is difficult
to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed
time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function
completely.
However, if these parts show any abnormality before the replacement interval has passed, they should be repaired
or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time
as the hoses.
In addition, carry out the checks for the hydraulic hoses other than periodic replacement parts. If any abnormality
is found, tighten the clamps or replace the parts.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.

4-13
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS MAINTENANCE

Replacement
No. Safety critical parts for periodic replacement Q’ty
interval

1 Fuel hose (fuel tank - water separator) 1

2 Fuel hose (water separator - priming pump) 1

3 Fuel return hose (injection pump - fuel tank) 1

4 Fuel spill hose (injectior - injectior) 5

5 Fuel spill hose (unit injectior - fuel tank) 1

6 Steering hose (pump - steering valve) 1

7 Steering hose (steering valve - steering cylinder) 4

8 Steering hose (steering valve - hydraulic tank) 2

9 Brake hose (pump - accumulator charge valve) 2

10 Brake hose (accumulator charge valve - check valve) 1

11 Brake hose (check valve - tandem valve) 2 Every 2 years or

12 Brake hose (check valve - single valve) 1 every 4000 hours,
whichever
13 Brake hose (check valve - accumulator P.P port) 1 comes first

14 Brake hose (tandem valve - front brake) 2

15 Brake hose (tandem valve - rear brake) 2

16 Brake hose (single valve - tandem valve) 1

17 Brake hose (tandem valve - drain block) 1

18 Brake hose (single valve - drain block) 1

19 Brake hose (drain block - hydraulic tank) 1

Brake hose
20 1
(brake accumulator - reduction valve for emergency parking brake cancel)

Brake hose
21 1
(transmission valve - reduction valve for emergency parking brake cancel)

22 Brake hose (charge valve drain - hydraulic tank) 1

4-14
MAINTENANCE MAINTENANCE SCHEDULE CHART

MAINTENANCE SCHEDULE CHART 0.

MAINTENANCE SCHEDULE CHART 0.
SERVICE PROCEDURE 0.
INITIAL 50 HOURS SERVICE ............................................................................................................................ 4-17
INITIAL 250 HOURS SERVICE .......................................................................................................................... 4-17
INITIAL 1000 HOURS SERVICE ........................................................................................................................ 4-17

WHEN REQUIRED 0.
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT ............................................................................. 4-18
CLEAN INSIDE OF COOLING SYSTEM............................................................................................................ 4-21
CHECK WATER SEPARATOR .......................................................................................................................... 4-24
CHECK TRANSMISSION OIL LEVEL, ADD OIL................................................................................................ 4-25
CHECK AXLE OIL LEVEL, ADD OIL .................................................................................................................. 4-26
CHECK AXLE CASE BREATHER ...................................................................................................................... 4-27
CLEAN CONDENSER OF AIR CONDENSER ................................................................................................... 4-27
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID ................................................................................ 4-28
CLEAN RADIATOR FINS AND COOLER FINS ................................................................................................. 4-28
CHECK ELECTRICAL INTAKE AIR HEATER.................................................................................................... 4-31
REPLACE BOLT ON CUTTING EDGE .............................................................................................................. 4-31
REPLACE BUCKET TEETH ............................................................................................................................... 4-32
CHECK AIR CONDITIONER .............................................................................................................................. 4-33
REPLACE SLOW-BLOW FUSE ......................................................................................................................... 4-34
SELECTION AND INSPECTION OF TIRES....................................................................................................... 4-35

CHECK BEFORE STARTING 0.

CHECK BEFORE STARTING............................................................................................................................. 4-37

EVERY 50 HOURS SERVICE 0.

DRAIN WATER, SEDIMENT FROM FUEL TANK .............................................................................................. 4-38

EVERY 100 HOURS SERVICE 0.

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ....................................................................................... 4-38
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER....................................................................... 4-39

EVERY 250 HOURS SERVICE 0.

CHECK BATTERY ELECTROLYTE LEVEL....................................................................................................... 4-40
CHECK PARKING BRAKE ................................................................................................................................. 4-42
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST ........................................................ 4-42
CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN....................................................................................... 4-43
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER............................................................. 4-43

EVERY 500 HOURS SERVICE 0.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ....................................... 4-44
REPLACE FUEL FILTER CARTRIDGE.............................................................................................................. 4-45

4-15
MAINTENANCE SCHEDULE CHART MAINTENANCE

EVERY 1000 HOURS SERVICE 0.

CHANGE TRANSMISSION OIL AND FILTER, CLEAN STRAINER................................................................... 4-46
CLEAN TRANSMISSION CASE BREATHER .................................................................................................... 4-47
CHECK TIGHTENING PARTS OF TURBOCHARGER ...................................................................................... 4-47
CHECK PLAY OF TURBOCHARGER ROTOR .................................................................................................. 4-47
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT ....................................................... 4-47
REPLACE CORROSION RESISTOR CARTRIDGE........................................................................................... 4-47

EVERY 2000 HOURS SERVICE 0.

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT ......................................... 4-48
REPLACE HYDRAULIC TANK BREATHER ELEMENT .................................................................................... 4-50
CHANGE AXLE OIL(*) ........................................................................................................................................ 4-51
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER .............. 4-51
CLEAN PPC CIRCUIT STRAINER ..................................................................................................................... 4-52
CLEAN ENGINE BREATHER ELEMENT ........................................................................................................... 4-52
CHEK ALTERNATOR, STARTING MOTOR ...................................................................................................... 4-52
CHECK ENGINE VALVE CLEARANCE, ADJUST ............................................................................................. 4-52
CLEAN AND CHECK TURBOCHARGER .......................................................................................................... 4-52
CHECK INJECTOR............................................................................................................................................. 4-53
CHECK ACCUMULATOR GAS PRESSURE ..................................................................................................... 4-53
CHECK VIBRATION DAMPER........................................................................................................................... 4-53
CHECK BRAKE DISC WEAR ............................................................................................................................. 4-54
*: The interval of 2000 hours for changing the axle oil is for standard operations. If the brake is used frequently or
the brakes make a sound, change the oil after a shorter interval.

EVERY 4000 HOURS SERVICE 0.

LUBRICATING .................................................................................................................................................... 4-55
CHECK WATER PUMP ...................................................................................................................................... 4-55
CHECK AIR CONDITIONER COMPRESSOR, ADJUST ................................................................................... 4-56
REPLACE INJECTOR NOZZLE TIP................................................................................................................... 4-56
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.......................... 4-56
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER........................... 4-56

EVERY 8000 HOURS SERVICE 0.

REPLACE HIGH-PRESSURE PIPING CLAMP .................................................................................................. 4-57
REPLACE FUEL SPRAY PREVENTION CAP ................................................................................................... 4-57

4-16
MAINTENANCE SERVICE PROCEDURE

SERVICE PROCEDURE 0.
INITIAL 50 HOURS SERVICE 0.
Carry out the following maintenance only after the first 50 hours.

CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN

If wheel hub nuts (1) are loose, tire wear will be increased and
accidents may be caused.
1. Check for loose nuts, and tighten if necessary.
When checking for loose nuts, always turn the nuts in the
direction of tightening to check.
Tightening torque: 825 to 1030 N·m (84 to 105 kgf·m)
2. If any stud bolt is broken, replace all the stud bolts for that
wheel.

INITIAL 250 HOURS SERVICE 0.

Carry out the following maintenance only after the first 250 hours.

CHANGE TRANSMISSION OIL FILTER CARTRIDGE

REPLACE HYDRAULIC FILTER ELEMENT

For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS and 2000 HOURS
SERVICE.

INITIAL 1000 HOURS SERVICE 0.

Carry out the following maintenance only after the first 1000 hours.

CHECK ENGINE VALVE CLEARANCE, ADJUST

For details of the method of replacing or maintaining, see the section on EVERY 2000 HOURS SERVICE.

4-17
SERVICE PROCEDURE MAINTENANCE

WHEN REQUIRED 0.
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT 0.

WARNING
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the
engine and the engine will suffer damage. Always stop the engine before carrying out these opera-
tions.
When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use safety glasses, dust mask, and other protective equipment.

CHECKING 0.
If air cleaner clogging caution lamp (1) on the machine monitor
lights up, clean the air cleaner element.

NOTICE
Do not clean the element until the air cleaner clogging cau-
tion lamp lights up.
If the element is cleaned frequently before the air cleaner
clogging caution lamp lights up, the air cleaner will not be
able to display its performance fully and the cleaning effi-
ciency will drop.
In addition, the frequency of dirt stuck to the element fall-
ing inside the inner element will increase.

It is also possible to check the condition of the air cleaner by

using the dust indicator installed to the air cleaner.

After cleaning or replacing the air cleaner, press the reset but-
ton at the top of the dust indicator to return the display to its
original position.

4-18
MAINTENANCE SERVICE PROCEDURE

CLEANING OUTER ELEMENT 0.

1. Open the top cover at the front of the engine side cover on
the right side of the machine.
2. Remove three clips (2), then remove dust cup (3).

3. Remove outer element (4).

NOTICE
Never remove inner element (5). If it is removed, dust will
enter and cause an engine trouble.

NOTICE
When cleaning the dust cup, do not remove evacuator
valve (6).

4. Clean the inside of the air cleaner body and dust cup.

NOTICE
The inner element must not be cleaned and used again.
When replacing the outer element, replace the inner ele-
ment at the same time.

5. Direct dry compressed air (less than 0.69 MPa (7 kg/cm²) to

the outer element (3) from inside along its folds, then direct
it from outside along its folds and again from inside
6. If small holes or thinner parts are found on the element
when it is checked by shining a light through it after clean-
ing, replace the element.

NOTICE
When cleaning the element, do not hit or beat it against
anything.
Do not use an element whose folds, gasket or seal are
damaged.

7. Set the cleaned outer element and install dust cup (3), then
secure them with clips (2).

4-19
SERVICE PROCEDURE MAINTENANCE

CAUTION
When installing the dust cup, check O-ring (7). If the O-ring has any defect, replace it.

8. Press the dust indicator button to return the yellow piston to its original position.
9. Close the top cover at the front of the engine side cover on the right side of the machine.
After cleaning, if the air cleaner clogging caution lamp lights up immediately or the yellow piston reaches the
red line (7.5 kPa), replace the inner and outer elements.

REPLACING ELEMENT 0.
1. Open the top cover at the front of the engine side cover on
the right side of the machine.
2. Remove three clips (2), then remove dust cup (3).

3. Remove outer element (4).

Do not remove inner element (5) at this time, however.

NOTICE
When cleaning the dust cup, do not remove evacuator
valve (6).

4. Clean the inside of the air cleaner body and dust cup.
5. Remove inner element (5), then install a new inner element
immediately.
6. Set new outer element (4) and install dust cup (3), then
secure them with clips (2).

CAUTION
When installing the dust cup, check O-ring (7). If the O-ring has any defect, replace it.

7. Press the dust indicator button to return the yellow piston to its original position.
8. Close the top cover at the front of the engine side cover on the right side of the machine.

4-20
MAINTENANCE SERVICE PROCEDURE

CLEAN INSIDE OF COOLING SYSTEM 0.

WARNING
Immediately after the engine is stopped, the engine coolant is hot and the pressure inside the radia-
tor is high. Removing the cap and draining the water under this condition could cause burns. Allow
the engine to cool down, then turn the cap slowly to release the pressure.
Start the engine and flush the system. When standing up or leaving the operator’s seat, set the safety
lock lever to the LOCK position.
For details of starting the engine, see “CHECK BEFORE STARTING ( 3-65 )“ and “STARTING ENGINE (
3-77 )“ in the OPERATION section of the Operation and Maintenance Manual.
When the undercover is removed, there is danger of touching the fan.
Never go to the rear of the machine when the engine is running.

Stop the machine on level ground when cleaning or changing the coolant.
Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the
table below.

NOTICE
Be sure to add Super Coolant (all season type anti-corrosive) to engine cooling water to prevent corrosion
in the engine cooling system.

Cleaning inside of cooling sys-

Kind of coolant Replacing corrosion resistor
tem and changing coolant
Every year (autumn) or
Permanent type antifreeze
every 2000 hours,
(All season type)
whichever comes first

Every 6 months (spring, Every 1000 hours and

Nom-permanent type anti-
autumn) when cleaning the inside of
freeze containing ethylene gly-
(Drain antifreeze in spring, the cooling system and
col (winter, one season type)
add antifreeze in autumn) when changine coolant.

Every 6 months or
When not using antifreeze every 1000 hours,
whichever comes first

Super Coolant (AF-ACL) has an anti-corrosion effect as well as an antifreeze effect.

The ratio of antifreeze to water depends on the ambient temperature, but to obtain the corrosion resistance effect,
a minimum ratio of 30% by volume is necessary.
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mix-
ing rate table given below.
It is actually better to estimate a temperature about 10°C lower when deciding the mixing rate.

Mixing rate of water and antifreeze

Min. atmospheric
°C - 10 -15 - 20 - 25 - 30
temperature

Amount of
Liters 10.8 12.6 14.4 16.2 18.0
antifreeze

Amount of water Liters 25.2 23.4 21.6 19.8 18.0

4-21
SERVICE PROCEDURE MAINTENANCE

WARNING
Antifreeze is flammable, so keep it away from flame.
Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on
you. If it gets in your eyes, flush your eyes with large quantities of fresh water and see a doctor at once.

Use city water for the cooling water.

If river water, well water or other such water supply must be used, contact your Komatsu distributor.
We recommend use of an antifreeze density gauge to control the mixing proportions.
Prepare the following:
Container to mix the coolant: Min 50 liters capacity
1. Stop the engine and close a valve (1) of the corrosion resis-
tor at two points.

2. Turn radiator cap (2) slowly to release the pressure, then

remove it.

3. Set a container in position to catch drained antifreeze mix-

ture, then open valve (3) under the left side of the fuel tank
and drain valve (4) at the side of the cylinder block to drain
cooling water.
4. After draining the coolant, close drain valves (3) and (4),
and fill with city water.
5. When the radiator is full, start the engine, and run it at low
idling.
Keep the engine running at low idling for 10 minutes until
the water temperature reaches more than 90°C.
6. Stop the engine, open drain valves (3) and (4), drain the
water, then tighten them again.
7. After draining the water, clean the cooling system with cleaning agent.
For the cleaning method, see the instructions for the cleaning agent.
8. Replace the corrosion resistor, then open a valve (1) of the corrosion resistor at two points.
For details of the procedure for replacing the corrosion resistor, see “REPLACE CORROSION RESISTOR
CARTRIDGE ( 4-47 )“.
9. Add cooling water until it overflows from the water filler.
Decide the proportions of antifreeze and water according to the table for the mixing rate of water and anti-
freeze.
10.To remove the air in the cooling system, run the engine for 5 minutes at low idling, and for another 5 minutes at
high adling. (When doing this, leave the radiator cap off.)

4-22
MAINTENANCE SERVICE PROCEDURE

11.Drain the coolant from sub-tank (5), clean the inside of the
sub-tank, then add water until the coolant level is between
the FULL and LOW marks.
12.Stop the engine, wait for approx. 3 minutes, then add tap
water until the water level is near the water filler port, and
tighten the cap. Check the coolant level and add water if
necessary.

4-23
SERVICE PROCEDURE MAINTENANCE

CHECK WATER SEPARATOR 0.

WARNING
Each part of the engine is still highly heated immediately after the engine is stopped. Do not attempt
to drain cooling water or remove the filter element cup.
High pressure is generated inside the engine fuel piping, while the engine is running. Wait for more
than 30 seconds after the engine stop for the engine to sufficiently cool down. Then start with drain-
ing cooling water or removing the filter element cup.
Do not bring fire close.

1. Open the engine side cover on the right side of the chassis.
2. Check the water separator to see that a red ring inside has
come up to the standard line.
3. If red ring (1) has come up to the standard line, carry out the
operation from Step 4 below.
4. Prepare a container to catch the drained fuel and set it
under the water separator.

5. Loosen drain valve (1) at the bottom of the water separator

and drain the water and fuel into the container.
6. Loosen ring nut (2), then remove element cup (3).
7. Remove element (4) from the separator base.
8. Wash the interior of filter element (4) and element cup (3)
with clean fuel.
9. Check element (4) and replace it if it is damaged.
10.Clean the water separator base, then fill washed element
cup (3) with clean fuel and install it on the water separator
base.
Be sure to use clean fuel for filling the element cup and take
care so that no dust will mix with it.

REMARK
Be careful not to lose the O-ring, float, or spring. Be sure
to assemble them after washing.

11. Install element (4) in the reverse sequence to the removing

process mentioned in the step 6.7.
The specified tightening torque of ring nut (2)
40 ± 3 N·m (4.1 ± 0.3 kgf·m)
If the ring is loose, it will cause leakage of fuel, so always
tighten it to the specified torque.
12.After installing filter element cup (3), bleed air in the follow-
ing manner.
13.Loosen air bleed plug (5) of the fuel filter.
14.Pump priming pump (6) until no more bubbles come out
with the fuel from air bleeder (5).
15.Tighten air bleed plug (5).
Tightening torque: 7.8 to 9.8 N·m (0.8 to 1 kgf·m)

4-24
MAINTENANCE SERVICE PROCEDURE

CHECK TRANSMISSION OIL LEVEL, ADD OIL 0.

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.
1. Start the engine and run it for at least 5 minutes.
2. Open the cap of oil filler port (F), remove dipstick (G), and
wipe the oil off with a cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.

4. The oil level should be between the H and L marks on dip-

stick (G).
If the oil level is below the L mark, add engine oil through oil
filler (F).

5. If the oil is above the H mark, drain the excess engine oil
from drain plug (P), and check the oil level again.
6. If the oil level is correct, insert dipstick (G) in the dipstick
guide, then tighten the cap

4-25
SERVICE PROCEDURE MAINTENANCE

CHECK AXLE OIL LEVEL, ADD OIL 0.

WARNING
When checking the oil level, apply the parking brake and secure the front and rear frames with the
safety bar.
After stopping the engine, the parts and oil are at a high temperature. Wait for the temperature to go
down before starting the operation.

Carry out this procedure if there is any sign of oil on the axle case.
Carry out the inspection with the machine on a horizontal road surface.
(If the road surface is at an angle, the oil level cannot be checked correctly.)
1. Stop the engine and remove oil level plug (1).

Front
REMARK
Remove the mud and dirt from around plug (1), then
remove the plug.

2. Wipe off any oil adhering to the oil level gauge attached to
plug (1) with cloth.

Rear

3. Set the oil level gauge (G) as shown in the right diagram.
4. The oil level is correct when it is between the two lines pro-
vided on the oil level gauge. Oil level
If the oil level does not reach the lower line, add axle oil measuring location
through filler port (F). (spot facing face)
Axle
assembly
REMARK
For axles with ASD (Anti-Slip Differential), the brand of
lubricating oil is different, so always use the specified
lubricating oil.

5. If the oil level is above the upper line, drain off the excess oil
through drain plug (P) and check the oil level again. Oil level range
6. If the oil level is correct, install plug (1).

Tightening torque: 127 to 177 N·m (13 to 18 kgf·m)

A portion detail

4-26
MAINTENANCE SERVICE PROCEDURE

CLEAN AXLE CASE BREATHER 0.

WARNING Front

When cleaning the axle breather, apply the parking brake

and secure the front and rear frames with the safety bar.

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). Rear
After removing the breather, take steps to prevent dirt or dust
from entering the mount.

CLEAN CONDENSER OF AIR CONDITIONER 0.

WARNING
Do not wash the condenser with a steam cleaner. There is danger that the condenser overheat.
If high-pressure water hits your body directly or dirt is sent flying the high-pressure water, there is
danger of personal injury. Always wear protective glasses, dust mask, and other protective equip-
ment.

If there is mud or dust on the air conditioner condenser, clean it with water.
If the water pressure is too high, the fins may get deformed. When washing with a high pressure washing
machine, apply the water from a reasonable distance.

WASHING METHOD
1. Open top cover (1) at the front of the engine hood.
2. Remove four bolts (3) on top of condenser (2).
3. Tilt condenser (2) back, holding its upper part. It will swing
with pin (4) at the lower part as a fulcrum.
4. Wash with water from the top.
5. Pull condenser (2) back to the original position and fit bolt
(3).

4-27
SERVICE PROCEDURE MAINTENANCE

CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID 0.

Check the washing fluid levels in washer tank (1). When the
fluid has run short, add automotive window washing fluid.

Be careful not to let dust get into the fluid.

CLEAN RADIATOR FINS AND COOLER FINS 0.

WARNING
Never open the engine side cover when the engine is running. Stop the engine completely before
starting the cleaning operation.
If compressed air, pressurized water, or steam hits your body directly, or causes dirt to fly, it may lead
to personal injury. Always wear safety glasses, dust mask, or other protective equipment.

Clean the radiator or cleaner if mud or dirt is stuck to it.

CLEAN FINS BY ROTATING COOLING FAN IN REVERSE 0.

NOTICE
When rotating the fan in reverse, be careful of flying dust
and take steps to prevent cloth or other objects from get-
ting caught in the fan.

On jobsites where the dust accumulates on to the radiator or

cooler, turn cooling fan reverse rotation switch (1) ON to rotate
the fan in the reverse direction and blow out the dust stuck to
the radiator or cooler. This can be used to extend the cleaning
interval.

METHOD OF ROTATING FAN IN REVERSE

NOTICE
When the engine is running, even if the switch is pressed, the direction of rotation of the fan does not
change, but the cooling fan reverse rotation pilot lamp on the machine monitor flashes. Stop the
engine, then operate the switch.
When the fan is rotating in reverse, the pilot lamp on the machine monitor lights up. Do not carry out
operations while the pilot lamp is lighted up. The machine will be unable to display its performance
fully and it may lead to overheating. For normal operations, always use the fan rotating in the normal
direction.
If the engine has to be stopped when the fan is rotating in reverse, run the engine at low idling, then
stop it.

1. Turn the starting switch to the OFF position and stop the engine.
2. Turn the starting switch to the ON position.

4-28
MAINTENANCE SERVICE PROCEDURE

3. Set cooling fan reverse rotation switch (1) to position (a)

(ON).

4. Check that the pilot lamp inside the switch and the cooling
fan reverse rotation pilot lamp on the machine monitor are
lighted up. At the same time, “COOLING FAN REVERSE“
is displayed on the character display, and the fan is set to
reverse rotation.
5. Turn the key in the starting switch to the START position
and start the engine.
The cooling fan will rotate in reverse.

6. Run the engine at high idling.

Select the time for running the engine at high idling as follows according to the condition of clogging.
Normal clogging: 1 to 2 minutes
Excessive clogging: 2 to 3 minutes
7. After completing the cleaning, run the engine at low idling for approx. 10 seconds.
8. Turn the starting switch to the OFF position and stop the engine.
9. After the fan stops turning, loosen wing bolt (2) and remove
wing bolt (3) to open cleaning cover (4).
10.Insert the air nozzle and blow the dirt out to the front of the
machine.

REMARK
Steam or water can be used instead of compressed air.

11.After blowing dirt out, install cleaning cover (4).

12.Run the engine at low idling.

13.Turn the key in the starting switch to the OFF position and stop the engine.
14.Turn the starting switch key to the ON position.
15.Set cooling fan reverse rotation switch (1) to position (b)
(OFF) to cancel the reverse rotation.
16.Check the rubber hose. Replace with a new one if the hose
is found to have cracks or to be hardened by ageing.
Further, check hose clamps for looseness.

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SERVICE PROCEDURE MAINTENANCE

CLEAN FINS WITH COMPRESSED AIR 0.

Tilt aftercooler (1) at the top front face of the radiator, swing oil
cooler (2) at the bottom, then insert the steam jet nozzle
through the gap and clean the fins.

METHOD OF TILTING AND SWINGING COOLER

1. Turn the starting switch to the OFF position and stop the engine.
2. Pull lever (3) down to release the lock, then use "AFTER-
COOLER TILT SWITCH ( 4-30 )".
Turn the knob (4) counterclockwise to release the lock, then
swing oil cooler (2).
If necessary, band (5) can be fitted to oil cooler (2) to hold it
in position after swinging it.
3. Use the steam jet nozzle to blow out the mud, dirt, or leaves
clogging the radiator fins or cooler fins.

NOTICE
If the steam jet nozzle is brought too close to the radiator fins, it may damage the fins, so keep the nozzle
a suitable distance away from the fins when cleaning.

4. Check the rubber hose. Replace with a new one if the hose is found to have cracks or to be hardened by age-
ing.
Further, check hose clamps for looseness.
5. Do as follows to blow out the mud or dirt that has fallen to the bottom.
6. Loosen wing bolt (6) and remove wing bolt (7) to open
cleaning cover (8).
7. Insert the air nozzle and blow the dirt out to the front of the
machine.

REMARK
Steam or water can be used instead of compressed air.

8. After blowing dirt out, install cleaning cover (8).

9. After completing the cleaning, push the bottom of after-
cooler (1) to lock it, then push the front of oil cooler (2) to
lock it.
Check that they are both securely locked in position.

AFTERCOOLER TILT SWITCH

For machines with the optional equipment, Step 2 of the
method for tilting and swinging the cooler can be used to tilt the
aftercooler electrically.
Press aftercooler switch on the left side of the engine room to
tilt the aftercooler electrically approx. 17 degrees; press (b) to
return the aftercooler to its original position.

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MAINTENANCE SERVICE PROCEDURE

CHECK ELECTRICAL INTAKE AIR HEATER 0.

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 BOLT ON CUTTING EDGE 0.

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.

Turn or replace the cutting edge before the wear reaches the edge of the bucket.
1. Raise the bucket to a suitable height, then put blocks under the bucket to prevent the bucket from coming
down.
Raise the bucket so that the bottom surface of the bucket is horizontal.
2. Remove nuts and bolts (1), then remove cutting edge (2).
3. Clean the mounting surface of cutting edge (2).
4. Turn cutting edge (2) and install it to the bucket. When turn-
ing the edge, install it to the opposite side (left edge to right
side, right edge to left side).
If both sides of the cutting edge are worn, replace with a
new part.
If the wear extends to the mounting surface, repair the
mounting surface before installing the cutting edge. Block

5. Tighten nuts and bolts (1) uniformly so that there is no gap

between the bucket and cutting edge.

Tightening torque for mounting bolt: 745 ± 108 N·m (76 ± 11 kgf·m)

6. Tighten the mounting bolts again after operating for several hours.

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SERVICE PROCEDURE MAINTENANCE

REPLACE BUCKET TEETH 0.

(If equipped)

WARNING
If the pin is hit out with strong force, there is danger that the pin may fly out. Check that there is no
one in the surrounding area.
There is danger of pieces flying during the replacement operation, so always wear protective cloth-
ing, such as safety glasses and gloves.

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 prevent the bucket from coming
down.
Raise the bucket so that the bottom surface of the bucket is horizontal.
2. Remove the bolt and nuts (1) and (2), then remove bucket
tooth (3).
3. Clean the installation surface of bucket tooth (3).
4. Install new teeth to the bucket.
When doing this, insert shims so that there is no clearance
between the teeth and the top surface of the bucket.
Continue to add shims until it becomes impossible to add a
0.5 mm shim.
If the mounting surface is worn, correct the mounting sur-
face before installing the teeth.
5. To prevent any gap from forming between the teeth and tip
of the bucket, tighten bolts and nuts (1) and (2) temporarily,
then hit the tip of the teeth with a hammer.

6. After operating the machine for a few hours, tighten the mounting bolts again.

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MAINTENANCE SERVICE PROCEDURE

CHECK AIR CONDITIONER 0.

CHECK LEVEL OF REFRIGERANT(GAS) 0.

WARNING
If the refrigerant used in the cooler gets into your eyes or
on your hands, it may cause loss of sight or frostbite. Do
not touch the refrigerant. Never loosen any part of the
refrigerant circuit.
Do not bring any flame close to any point where the refrig-
erant gas is leaking.

If there is a lack of refrigerant (gas), the cooling performance

will be poor. When operating the cooler at high speed with the
engine at full throttle, use the receiver sight glass (inspection Sight glass
window) to check the condition of the refrigerant gas (Freon A
R134a) flowing in the refrigerant circuit.
No bubbles in refrigerant flow: Suitable B
Some bubbles in flow (bubbles pass continuously): Lack of
refrigerant
Colorless, transparent: No refrigerant C
A : Suitable
B : Lack of refrigerant Receiver
C: No refrigerant (colorless, transparant)
REMARK
When there are bubbles, the refrigerant gas level is low, so contact your refrigerant dealer to have refriger-
ant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the com-
pressor.

OPERATING THE AIR CONDITIONER OFF SEASON 0.

Even during the off-season, operate the air conditioner for 3 - 5 minutes once a month to maintain the oil film at all
parts of the compressor.

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SERVICE PROCEDURE MAINTENANCE

REPLACE SLOW-BLOW FUSE 0.

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. Turn the starting switch to the OFF position.

2. Remove the slow blow fuse box from the chassis.

3. Open covers (1), (2), and (3) of the slow blow fuse box.
Covers (2) and (3) can be removed easily by using protru-
sion (A) on the body as a fulcrum and levering the catch of
the cover with a flat-headed screwdriver to release it.
4. Loosen screws (4) and (5), and remove.
When screws (4) and (5) are removed, slow blow fuse 6 will
also come off together with electric wiring (7) and (8).
5. Using screws (4) and (5), install a new slow blow fuse
together with electric wiring 7 and 8 to the slow blow fuse
box, then close covers (1), (2), and (3).
6. Install the slow blow fuse box to the chassis.

4-34
MAINTENANCE SERVICE PROCEDURE

SELECTION AND INSPECTION OF TIRES 0.

WARNING
If a tire or a rim is handled wrongly, the tire may burst or
may be damaged and the rim may be broken and scat-
tered, and that can cause serious injury and death.
Since maintenance, disassembly, repair and assembly
of the tires and rims require special equipment and
skill, be sure to ask a tire repair shop to carry out the
work.
Do not heat or weld the rim to which the tire is
installed. Do not make a fire near the tire.

SELECTION OF TIRES 0.

WARNING
Select the tires according to the conditions of use and attachments on the machine. Use only specified
tires and inflate them to the specified pressure.

Select the tires according to the conditions of use and attachments of the machine. Use the following table.
Since the indicated speed varies with the tire size, consult your Komatsu distributor when using optional tires.

Maximum load [kg] Tire size Remarks

Front
7,720 20.5-25-16PR (L3 Rock)
wheel
Standard
Rear
7,720 20.5-25-16PR (L3 Rock)
wheel
Front
9,095 23.5-25-16PR (L3 Rock)
If wheel
equipped Rear
9,095 23.5-25-16PR (L3 Rock)
wheel

The specified air pressure values might deviate from the standard values under special conditions. If this is the
case, please contact an authorised Komatsu dealer.

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SERVICE PROCEDURE MAINTENANCE

CHECK INFLATION PRESSURE OF TIRES 0.

WARNING
When inflating a tire, check that no one will enter the
working area and use an air chuck which has a clip and
which can be fixed to the air valve.
While inflating the tire, check the inflation pressure
occasionally so that it will not rise too high.
If the rim is not fitted normally, it may be broken and
scattered while the tire is inflated. To ensure safety,
place a guard around the tire and do not work in front
of the rim but work on the tread side of the tire.
Abnormal drop of inflation pressure and abnormal fit-
ting of the rim indicate a trouble in the tire or rim. In
this case, be sure to ask a tire repair shop to carry out
repairs.
Be sure to observe the specified inflation pressure.
Do not adjust the inflation pressure of the tires just
after high-speed travel or heavy-duty work.

Check 0.
Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.

Inflation of tires 0.
Adjust the inflation pressure properly.
When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not
work in front of the rim but work on the tread side of the tire.
The proper inflation pressure is shown below.

Tire size Inflation pressure

20.5-25-16PR
Front Tire: 0.34 MPa (3.5 kgf/cm²)
(L3 Rock)
Rear Tire: 0.34 MPa (3.5 kgf/cm²)
(standard)

23.5-25-16PR
Front Tire: 0.30 MPa (3.1kgf/cm²)
(L3 Rock)
Rear Tire: 0.30 MPa (3.1kgf/cm²)
(if equipped)

NOTICE
The optimum inflation pressure differs according to the type of work. For details, see “HANDLING THE
TIRES ( 3-109 )“ .

The specified air pressure values might deviate from the standard values under special conditions. If this is the
case, please contact an authorised Komatsu dealer.

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MAINTENANCE SERVICE PROCEDURE

CHECK BEFORE STARTING 0.

For the following items, see “CHECK BEFORE STARTING ( 3-67 )“.
Checking with machine monitor
Check coolant level, add water
Check oil level in engine oil pan, add oil
Check fuel level, add fuel
Check electrical wiring
Check parking brake
Check brake pedal
Check tire inflation pressure

4-37
SERVICE PROCEDURE MAINTENANCE

EVERY 50 HOURS SERVICE 0.

DRAIN WATER, SEDIMENT FROM FUEL TANK 0.
Loosen valve (1) on the right side of the tank so that the sedi-
ment and water will be drained together with fuel.

EVERY 100 HOURS SERVICE 0.

Maintenance for every 50 hours service should be carried out at the same time.

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL 0.

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause burns.Wait for
the temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

1. Lower the bucket horizontally to the ground and stop the

engine. Wait for 5 minutes, then check sight gauge (G).
The oil level should be between the H and L marks.

NOTICE
Do not add oil if the level is above the H line. If the oil has
been added to above H level, stop the engine and wait for
the hydraulic oil to cool down, then drain the excess oil
from the drain plug. If the oil is above H level, it will dam-
age the hydraulic circuit or cause the oil to spurt out.

2. If the oil is below the L level, open the inspection cover

above the step and add oil through oil filler port (F).

4-38
MAINTENANCE SERVICE PROCEDURE

CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER 0.

WARNING
If compressed air is used, there is danger that dirt may fly and cause personal injury.
Always wear safety glasses, dust mask, and other protective equipment.

If the air conditioner has been used, the air filter should be cleaned.
Stop the air conditioner before cleaning the element.
1. Push handle (1) and open cover (2).

2. Remove element (3) and clean it.

3. Direct dry compressed air (less than 0.69 MPa (7 kgf/ cm²)
to the element from inside along its folds, then direct it from
outside along its folds and again from inside.

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SERVICE PROCEDURE MAINTENANCE

EVERY 250 HOURS SERVICE 0.

Maintenance for every 50 and 100 hours service should be carried out at the same time.

CHECK BATTERY ELECTROLYTE LEVEL 0.

Carry out this check before operating the machine.

WARNING
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accel-
erate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it
may also cause an explosion.
The battery generates flammable gas and there is danger of explosion, so do not bring fire or sparks
near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amount
of water and consult a doctor.
When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER
LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or
corrode other parts.

NOTICE
When adding distilled water in cold weather, add it before starting operations in the morning to prevent
the electrolyte from freezing.

Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.

WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY 0.

If it is possible to check the electrolyte level from the side of the battery, check as follows.
1. Open the cover of the battery box.
There are two battery boxes: One on each side at the rear of the machine.
2. Use a wet cloth to clean the area around the electrolyte
level lines and check that the electrolyte level is between
the UPPER LEVEL (U.L) and LOWER LEVEL (L.L) lines.
If the battery is wiped with a dry cloth, static electricity may
cause a fire or explosion.

Upper level
Lower level

3. If the electrolyte level is below the midway point between

the U.L and L.L lines, remove cap (1) and add distilled water
to the U.L line.
4. If distilled water has been added to any cell of cap (1), add
distilled water also to the other cells.
5. Clean the vents of the battery caps, then close the caps
securely.
Keep the top of the battery clean and wipe it with a wet
cloth.

REMARK
If distilled water is added to above the U.L line, use a pipette 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.

4-40
MAINTENANCE SERVICE PROCEDURE

WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY 0.

If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER
LEVEL line on the side of the battery, check as follows.
1. Open the cover of the battery box.
There are two battery boxes: One on each side at the rear of the machine.
2. Remove cap (1) at the top of the battery, look through the
water filler port, and check the electrolyte surface. If the
electrolyte does not reach the sleeve, add distilled water so
that the level reaches the bottom of the sleeve (UPPER
LEVEL line) without fail.
3. If distilled water has been added to any cell of cap (1), add
distilled water also to the other cells.

Use the diagram below for reference, and check if the electro-
lyte reaches the bottom of the sleeve.

Correct level Filler port

The electrolyte level is up to the bottom of the
A
sleeve, so the surface tension causes the surface
to rise and the plate appears to be warped. Sleeve A
Upper
Lower
Too low (level)
B The electrolyte level is not up to the bottom of the
sleeve, so the plate appears to be normal.
B

4. After adding distilled water, tighten cap (1) securely.

REMARK
If distilled water is added to above the bottom of the sleeve, use a pipette to lower the level to the bottom
of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with
a large amount of water or consult your Komatsu distributor or battery maker.

WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL 0.

If it is possible to use and indicator to check the electrolyte level, follow the instructions given.

4-41
SERVICE PROCEDURE MAINTENANCE

CHECK PARKING BRAKE 0.

1. Set the machine on a dry downhill slope, press the parking
brake switch to the ON position, and check if the parking
brake hold the machine in positon.
2. If any abnormality is found, please contact your Komatsu
distributor.

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST 0.

CHECKING 0.
The standard deflection between the air conditioner compres-
sor pulley and crank pulley when pressed with a thumb
(approx. 98 N (10 kgf)) should be approx. 11 to 15 mm.
When a belt tension gauge is used, the standard tension is
within a range of 353 to 530 N (36 to 54 kgf).

CHECK WHEN CHANGING THE V-BELT 0.

The standard deflection between the air conditioner compressor pulley and fan pulley when pressed with a thumb
(approx. 98 N (10 kgf)) should be approx. 8 to 11.5 mm.
When a belt tension gauge is used, the standard tension is within a range of 530 to 745 N (54 to 76 kgf).

REMARK
When the belt has been replaced with a new part, a high tension is necessary, so the initial tension is in
the value given above.

ADJUSTING 0.
1. For adjustment, loosen bolt (1) and shift air compressor (2).
2. Tighten nut (1) to fix air compressor (2).
3. Check each pulley for damage, wear of the V-groove, and
wear of the V-belt. Be particularly careful to check that the
V-belt is not in contact with the bottom of the V-groove.
4. Replace the V-belt if it has stretched, leaving no allowance
for adjustment, or if the belt is cut or cracked.
If the V-belt has been replaced with a new part, there will be
initial elongation, so inspect and adjust it again after one-
hour of operation.

4-42
MAINTENANCE SERVICE PROCEDURE

CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN 0.

If wheel hub nuts (1) are loose, tire wear will be increased and
accidents may be caused.
1. Check for loose nuts, and tighten if necessary.
When checking for loose nuts, always turn the nuts in the
direction of tightening to check.
Tightening torque: 825 to 1030 N·m (84 to 105 kgf·m)
2. If any stud bolt is broken, replace all the stud bolts for that
wheel.

CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER 0.

1. Loosen knob (1), remove filter inspection cover (2), then

open filter inspection cover (3).

2. Pull out filters (4) and (5) in the direction of the arrow.
3. Clean with compressed air in the same way as for the fresh
air filter.
If the filter is extremely dirty, rinse it in water.
After rinsing the filter, dry it completely before installing it
again.

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SERVICE PROCEDURE MAINTENANCE

EVERY 500 HOURS SERVICE 0.

Maintenance for every 50, 100 and 250 hours service should be carried out at the same time.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 0.

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause burns.Wait for
the temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

Refill capacity: 32 liters

Filter wrench

1. Open the engine side cover on the right side of the chassis.
2. Open oil filler (F).
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 parti-
cles or foreign material, please contact your Komatsu dis-
tributor.
6. Install drain plug (P).

7. Open the engine side cover on the left side of the chassis.
8. Using the filter wrench, turn filter cartridge (1) counterclock-
wise to remove it.
In particular, if this operation is carried out immediately after
stopping the engine, a large amount of oil will come out, so
wait for 10 minutes before starting the operation.
9. Clean the filter holder, fill the new filter cartridge with engine
oil, then coat the seal and thread of the filter cartridge with
engine oil (or coat thinly with grease)and install.
10.When installing the seal, tighten it by 3/4 turn, after its sur-
face comes to contact with the filter holder.
11. After replacing the filter cartridge, add engine oil through oil
filler (F) until the oil level is between the H and L marks on
the dipstick (G).
12.Run the engine at idling for short time, then stop the engine,
and check the oil is between the H and L marks on the dip-
stick. For details, see “CHECK OIL LEVEL IN ENGINE OIL
PAN, ADD OIL ( 3-69 )“.

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MAINTENANCE SERVICE PROCEDURE

REPLACE FUEL FILTER CARTRIDGE 0.

WARNING
Each part of the engine is still highly heated immediately after the engine is stopped. Do not attempt
to replace filter elements hastily, but wait for the engine to sufficiently cool down.
High pressure is generated inside the engine fuel piping, while the engine is running. Wait for more
than 30 seconds after the engine stop for the engine to sufficiently cool down. Then start with replac-
ing the filter elements.
Do not bring fire close.
Be sure to use genuine Komatsu fuel filter cartridge. There is the danger that a trouble occurs in the
fuel injection system, if a non-genuine product is used. Use of non-genuine parts must be definitely
avoided.
Be careful when unscrewing the air bleeding plug on the fuel filter head. Oil may spurt out due to the
residual pressure inside the tank.

Container to catch the oil

Filter wrench

1. Set the container to catch the fuel under the filter cartridge.
2. Using a filter wrench, turn filter cartridge (1) counterclock-
wise to remove it.
3. Clean the filter head, fill the new filter cartridge with clean
fuel, coat the packing surface thinly with engine oil, and
install it to the filter holder.
Always use clean fuel when filling with fuel, and be careful
not to let any dirt or dust get in.
Add fuel from small hole (A) (dirty side) at eight places. Do
not add fuel from hole (B) (clean side) at the center.
4. When installing the seal, tighten it by 3/4 turn, after its sur-
face comes to contact with the filter holder.
If the filter cartridge is tightened too far, the packing will be
damaged and this will lead to leakage of fuel. If the filter car-
tridge is too loose, fuel will also leak from the packing, so
always tighten to the correct amount.After replacing filter
cartridge (1), loosen air bleed plug (2).

5. Bleed air with priming pump (4) and check that air bubbles
come out of air bleeding plug (3), followed by fuel.
6. Tighten air bleed plug (2).
Tightening torque: 7.8 to 9.8 N·m (0.8 to 1 kgf·m)
7. After replacing the filter cartridge, start the engine and
check that there is no leakage of fuel from the filter seal sur-
face. If there is any leakage of fuel, check the tightening of
the filter cartridge. If there is still leakage of fuel, follow Step
1 and 2 to remove the filter cartridge, then check the pack-
ing surface for damage or foreign material. If any damage or
foreign material is found in the packing, replace the car-
tridge with a new part, then repeat Steps 3 - 8 to install the
filter cartridge.

4-45
SERVICE PROCEDURE MAINTENANCE

EVERY 1000 HOURS SERVICE 0.

Maintenance for every 50, 100, 250 and 500 hours service should be carried out at the same time.

CHANGE TRANSMISSION OIL AND FILTER, CLEAN STRAINER 0.

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause burns.Wait for
the temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

Refill capacity: 54 liters

Filter wrench

1. Set a container to catch the oil under drain plug (P), then
remove drain plug (P) and drain the oil.
To prevent the oil from pouring out suddenly, loosen drain
plug (P) and remove it gradually.
2. After draining the oil, install drain plug (P).
Tightening torque: 68.6 ± 9.8 N·m (7.0 ± 1.0 kgf·m)
3. Set a container to catch the oil under the transmission filter.

4. Remove drain plug (1) of the transmission filter, drain the

oil, then tighten the plug again.
5. Using a filter wrench, turn filter cartridge (2) to the left to
remove it.
6. Clean in the filter holder, coat the seal surface and thread of
the new filter cartridge with engine oil, then install it.
7. When the seal surface comes into contact with the filter
holder, tighten a further 2/5 turns with the filter wrench.

8. Remove 4 bolts (3), move tube (4), then remove strainer

(5).
9. Remove any dirt stuck to strainer (5), then wash it in clean
diesel fuel or flushing oil. If strainer (5) is damaged, replace
it with a new part.
10.Install strainer (5) in the case.
Replace the O-ring of tube (4) with a new part, then install
tube (4).

11. Pour in the specified amount of engine oil from oil filler (F).
12.After filling with oil, check that the oil is at the specified level.
For details, see “CHECK TRANSMISSION OIL LEVEL,
ADD OIL ( 4-25 )“.
13.Check that there is no leakage of oil from the transmission
case or oil filter.

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MAINTENANCE SERVICE PROCEDURE

CLEAN TRANSMISSION CASE BREATHER 0.

1. Open cover (1) on the cab side of the engine hood.
2. Remove the mud and dirt from around the breather, then
remove breather (2), soak it in washing liquid and wash it.
After removing the breather, take steps to prevent dirt or
dust from entering the mount.

CHECK TIGHTENING PARTS OF TURBOCHARGER 0.

Please contact your Komatsu distributor to have the tightening portions checked.

CHECK PLAY OF TURBOCHARGER ROTOR 0.

Please contact your Komatsu distributor to have the rotor play checked.

CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT 0.

Since check and replacement of the fan belt require special tools, ask Komatsu or your Komatsu distributor.

REMARK
The machine is equipped with an auto tensioner, so there is no need to adjust the tension.

REPLACE CORROSION RESISTOR CARTRIDGE 0.

1. Close a valve (1) of the corrosion resistor at two points.
2. Using a filter wrench, turn cartridge (2) to the left to remove
it.
3. Apply engine oil to the sealing surface of a new cartridge,
then install it to the filter holder.
4. Bring the packing surface into contact with the seal surface
of the filter holder, then tighten a further approx. 2/3 turns.
5. Open a valve (1) of the corrosion resistor at two points.

4-47
SERVICE PROCEDURE MAINTENANCE

EVERY 2000 HOURS SERVICE 0.

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 0.

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause burns.Wait for
the temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

Refill capacity: 129 liters

1. Lower the bucket horizontally to the ground and apply the parking brake, then stop the engine.
2. Remove bolts (1), then remove cover (2).
3. Remove the cap of oil filler (F).

4. Set a container to catch the oil under drain plug (3).

5. Remove drain plug (3).
6. Open drain valve (4) gradually and drain the oil.
7. After draining the oil, close drain valve (4), then tighten
drain plug (3).

Tightening torque
Drain plug (3): 68.6 ± 9.8 N·m (7.0 ± 1.0 kgf·m)
Drain valve (4): 63.7 ± 14.7 N·m (6.5 ± 1.5 kgf·m)

4-48
MAINTENANCE SERVICE PROCEDURE

8. Remove mounting bolts (6) of filter cover (5) at the top of

the tank, then remove the cover.
When the cover is removed, the force of spring (7) may
make the cover fly off, so keep the cover pushed down
when removing the bolts.
9. Remove spring (7) and bypass valve (8), then remove ele-
ment (9).
10.Check that there is no foreign material inside the tank, then
clean it.
11.Install new element (9), then set bypass valve (8), spring
(7), and cover (5) to the tank.
If the O-ring of the cover is damaged or deteriorated,
replace it.
12.When installing the cover bolts, push down the cover and
tighten the bolts evenly.
13.Add engine oil through oil filler port (F) to the specified level,
then install cap (F).
14.Check that the hydraulic oil is at the standard level. For
details, see “CHECK OIL LEVEL IN HYDRAULIC TANK,
ADD OIL ( 4-38 )“.
15.Run the engine at low idling,and extend and retract the
steering, bucket, and lift arm cylinders 4 to 5 times. Be
careful not to operate the cylinder to the end of its stroke
(stop approx.100 mm) before the end of stroke).
NOTICE
If the engine is run immediately at high speed or the cylinder is operated to the end of its stroke,the air
inside the cylinder will cause damage to the piston packing.

16.Next, operate the steering, bucket, and lift arm cylinders to

the end of their stroke 3 to 4 times, then stop the engine and
loosen bleed plug (10) to bleed the air from the hydraulic
tank. After bleeding the air, tighten plug (10) again.
Run the engine at low idling when bleeding the air.
17.Check that the hydraulic oil is at the standard level. For
details, see “CHECK OIL LEVEL IN HYDRAULIC TANK,
ADD OIL ( 4-38 )“.
18.Next, increase the engine speed and repeat the procedure
in Step 16 to bleed the air. Continue this operation until no
more air comes out from plug (10).
19.After completing the air bleed operation, tighten plug (10).
Tightening torque: 11.3 ± 1.5 N·m (1.15 ± 0.15 kgf·m)

20.Check that the hydraulic oil is at the standard level. For details, see “CHECK OIL LEVEL IN HYDRAULIC
TANK, ADD OIL ( 4-38 )“.
21.Check that there is no leakage of oil from the filter cover mount.

4-49
SERVICE PROCEDURE MAINTENANCE

REPLACE HYDRAULIC TANK BREATHER ELEMENT 0.

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause burns.Wait for
the temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

1. Before removing the breather, wipe off all the dirt from
around the breather.
2. Remove the cap of oil filler (F).
3. Remove nut (2) of breather (1), then remove cover (3).
4. Replace filter element (4) with a new part, then install cover
(3) and nut (2).
5. Tighten the cap of oil filler (F).

REMARK
It is possible to replace the element with the breather
installed in the tank. However, if the breather is removed,
do not wrap the taper thread of the breather with seal tape
when assembling again, and be careful not to tighten too
much.

4-50
MAINTENANCE SERVICE PROCEDURE

CHANGE AXLE OIL 0.

WARNING
When changing the oil, apply the parking brake and secure the front and rear frames with the safety
bar.
After the engine is stopped, the parts and oil are at high temperature, and may cause burns. Wait for
the temperature to go down before starting the operation.
When the plug is removed, oil may spurt out, so turn it slowly to release the internal pressure, then
remove it carefully.

Refill capacity (front and rear, each): 38 liters

1. Set a container to catch the oil under drain plug (P).

2. Remove front and rear oil filler plugs (1), then remove drain Front
plug (P) to drain the oil.

REMARK
Remove the mud and dirt from around plug (1), then
remove the plug.

3. After draining the oil, clean drain plug (P) and install it again.
4. Add axle oil through plug hole (1) at the specified level.

REMARK
Rear
For axles with ASD (Anti-Slip Differential), the brand of
lubricating oil is different, so always use the specified
lubricating oil.

5. After adding oil, check at level plug (1) that the oil is at the
specified level. For details, see “CHECK AXLE OIL LEVEL,
ADD OIL ( 4-26 )“.

REMARK
For operations where the brake is used frequently, change the axle oil at shorter intervals.

REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH

AIR FILTER 0.

Remove both the recirculation air filter and fresh air filter in the same way as when cleaning, and replace them with
new parts.

For details of cleaning the recirculation air filter, see “CLEAN ELEMENT IN AIR CONDITIONER RECIRCULA-
TION FILTER ( 4-43 )“.
For details of cleaning the fresh air filter, see “CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER ( 4-
39 )“.

4-51
SERVICE PROCEDURE MAINTENANCE

CLEAN PPC CIRCUIT STRAINER 0.

WARNING
After the engine is stopped, the parts and oil are at high temperature, and may cause burns. Wait for
the temperature to go down before starting the operation.
When the rubber hose is removed, oil may spurt out, so turn it slowly to release the internal pressure,
then remove it carefully.

1. Remove a cover under the floor frame at the left side of

machine.
2. When rubber hose (1) and flange (2) are removed, oil will
spill out, so set a container (capacity: approx. 300 cc) in
position to catch the oil.
3. Remove rubber hose (1) and flange (2).
4. Remove strainer (3) and wash it in clean diesel oil.
5. Assemble strainer (3) in strainer case (4) with the strainer
protrusion side (O-ring side) facing the front and fix it with
flange (2).

6. Install rubber hose (1).

7. Install the cover.

CLEAN ENGINE BREATHER ELEMENT 0.

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.

1. Wipe away dust around the breather.

2. Loosen the clamp and remove the hose. Remove breather
(1).
3. Clean the breather body with light oil or cleaning oil.
4. Replace O-ring with new one. Coat a new O-ring with
engine oil, set it, then install breather (1).
5. Check the breather hose and pipe. If caked oil (sludge)
adhere to insides, replace the hose and pipe with new parts.

CHEK ALTERNATOR, STARTING MOTOR 0.

The brush may be worn or may be 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.

CHECK ENGINE VALVE CLEARANCE, ADJUST 0.

As special tool is required for removing and adjusting the parts, request your Komatsu distributor for service.

CLEAN AND CHECK TURBOCHARGER 0.

If there is carbon or oil sludge stuck to the blower impeller, it will lower the performance of the turbochargeror
cause it to break, so ask your Komatsu distributor to carry out the cleaning.

4-52
MAINTENANCE SERVICE PROCEDURE

CHECK INJECTOR 0.
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 ( 3-131 )“.

CHECK ACCUMULATOR GAS PRESSURE 0.

When carrying out the EVERY 2000 HOURS SERVICE or EVERY YEAR SERVICE or when making periodic
replacement of the critical safety parts, please ask your Komatsu distributor to check the accumulator gas pres-
sure.

CHECK VIBRATION DAMPER 0.

Check that there are no cracks or peeling in the outside surface of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.

4-53
SERVICE PROCEDURE MAINTENANCE

CHECK BRAKE DISC WEAR 0.

WARNING
When checking the brake disc wear, apply the parking brake and secure the front and rear frames with
the safety bar.
Make sure that the brake oil temperature is less than 60°C before checking the brake wear.
If the disc is near the wear limit, carry out inspection at shorter intervals, regardless of the specified
inspection interval.

When checking the brake disc for wear, there are 4 places (front axle and rear axle, left and right), so use the
same procedure to check all 4 places.
1. Remove cap nut (1).

2. Depress the brake pedal, keep it depressed, and push in

the rod (2) of the gauge until contacts the piston.
3. The wear is the amount that the end face of rod (2) is pro-
truding from the end face of guide (3). Measure the amount
End face
of protrusion. of guide Groove
The point where the rod groove is level with the end face of
the guide is the permissible limit for the disc wear. End face
If the wear has reached this point, please ask your Komatsu of rod
distributor for inspection and replacement parts.
If the disc is near the wear limit, carry out inspection at
shorter intervals, regardless of the specified inspection
interval.
4. Install cap nut (1).
Tightening torque: 29.4 to 39.2 N·m (3.0 to 4.0 kgf·m)

Amount of wear
Permissible wear limit

REMARK
On new machines, the position of the guide is adjusted so that the end face of rod (2) comes to the end
face of guide (3). For this reason, do not loosen locknut (4) except when replacing the disc.
Carry out the operation with two workers: one worker depresses the brake pedal and the other worker
pushes in rod (2).

4-54
MAINTENANCE SERVICE PROCEDURE

EVERY 4000 HOURS SERVICE 0.

Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time.

LUBRICATING 0.
Carry out the greasing once every two years, regardless of whether the 4000 hour interval has passed.
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.
(1)Center drive shaft spline (1 point)

(2)Front drive shaft (2 points)

(3)Rear drive shaft (2 points)

(4)Center drive shaft (2 points)

CHECK WATER PUMP 0.

Check that there is no play in the pulley or any grease leakage, water leakage, or clogging of the drain hole. If any
abnormality is found, contact your Komatsu distributor for disassembly and repair or replacement.

4-55
SERVICE PROCEDURE MAINTENANCE

CHECK AIR CONDITIONER COMPRESSOR, ADJUST 0.

As special tool is required for checking and adjusting the parts, request Komatsu distributor for service.

REPLACE INJECTOR NOZZLE TIP 0.

Ask your Komatsu distributor to carry out this work.

CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF

RUBBER 0.

Check visually and touch with your fingers to check that there are no loose bolts or hardening of rubber parts at
clamps (1) to (4). If there is any looseness or hardened rubber, contact your Komatsu distributor for replacement.

CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUB-

BER 0.

Check if any of fuel spray prevention caps (1) through (12) is missing, or if any part of the rubber is hardened. If
either of the cases is found, call your Komatsu distributor for the installation or replacement.

4-56
MAINTENANCE SERVICE PROCEDURE

EVERY 8000 HOURS SERVICE 0.

Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time.

REPLACE HIGH-PRESSURE PIPING CLAMP 0.

Ask your Komatsu distributor to carry out this work.

REPLACE FUEL SPRAY PREVENTION CAP 0.

Ask your Komatsu distributor to carry out this work.

4-57
SERVICE PROCEDURE MAINTENANCE

4-58
TECHNICAL DATA
35
TECHNICAL DATA TECHNICAL DATA

TECHNICAL DATA 0.
WA380-5H

WA380-5H standard specification

Item Unit machine
(when using POWER mode)
Operating weight (including 1 operator: 80 kg
kg (lbs) 17.765 (39,164)
(176 lb).)(with bolt on cutting edge)
Normal load kg (lbs) 5.280 (11,640)
Bucket capacity m³ (cu yd) 3,1 (4.1)
Engine model - Komatsu SAA6D114E-2 diesel engine
kW (HP)/
Flywheel horsepower 140 (188) / 2,000
rpm
A Overall length mm (ft in) 8.120 (26’ 8")
B Overall height mm (ft in) 3.374 (11’ 1")
C Max. dimension when shanking bucket mm (ft in) 5.450 (17’ 11")
D Overall width mm (ft in) 2.695 (8’ 10")
E Min. ground clearance mm (ft in) 449 (1’ 6")
F Bucket width mm (ft in) 2.926 (9’ 7")
G Clearance Cutting edge [BOC tip] mm (ft in) 2.970 [2.815] (9’ 9" [9’ 3"])
H Reach Cutting edge [BOC tip] mm (ft in) 1.080 [1.235] (3’ 7" [4’ 1"])
I Dump angle degrees 45
Cutting edge mm (ft in) 6.580 (21’ 7")
Turning radius
At corner of tyres mm (ft in) 5.925 (19’ 5")
1st km/h (mph) 6,8 (4.2)
2nd km/h (mph) 12,3 (7.6)
Forward
3rd km/h (mph) 22,6 (14.0)
Travel speed
4th km/h (mph) 38,3 (23.8)
with 23.5 R25tyres
1st km/h (mph) 7,3 (4.5)
2nd km/h (mph) 12,8 (8.0)
Reverse
3rd km/h (mph) 23,9 (14.9)
4th km/h (mph) 39,4 (24.5)
Lift circuit
Hydraulic pressure Tilt circuit bar 210
Third control circuit

5-2
TECHNICAL DATA TECHNICAL DATA

5-3
NOISE EMISSION LEVELS TECHNICAL DATA

NOISE EMISSION LEVELS 0.

Two labels indicating the machine noise level are affixed on the
machine.
Sound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle).

Sound power level emitted by the machine, measured

according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.

VIBRATION LEVELS 0.
When used for its intended purpose, levels of vibration for the
earth-moving machine transmitted from the operator’s seat are
lower than or equal to the tested vibrations for the relative
machinery class in compliance with ISO 7096.
The actual acceleration value for the hands and arms is less
than or equal to 2.5 m/s². The actual acceleration value for the
body is less than or equal to 0.5 m/s².
These values were determined using a representative machine
and measured during the typical operating condition indicated
below according to the measurement procedures that are
defined in the standards ISO 2631/1 and ISO 5349.

OPERATING CONDITION: 0.
V-shape loading

GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE 0.

The following guides can help an operator of this machine to
reduce the whole body vibration levels:

1) Use the correct equipment and attachments.

2) Maintain the machine according to this manual

Tire pressures (for wheeled machines), tension of

crawler (for crawler machines)
Brake and steering systems
Controls, hydraulic system and linkages

5-4
TECHNICAL DATA VIBRATION LEVELS

3) Keep the terrain where the machine is working and trav-

eling in good condition

Remove any large rocks or obstacles

Fill any ditches and holes
Site manager should provide machine operators with
machine and schedule time to maintain terrain condi-
tions

4) Use a seat that meets ISO 7096 and keep the seat main-
tained and adjusted

Adjust the seat and suspension for the weight and

size of the operator
Wear seat belt
Inspect and maintain the seat suspension and adjust-
ment mechanisms

5) Steer, brake, accelerate, shift gears (for wheeled

machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly

6) Adjust the machine speed and travel path to minimize

the vibration level

When pushing with bucket or blade, avoid sudden

loading; load gradually
Drive around obstacles and rough terrain conditions
Slow down when it is necessary to go over rough ter-
rain
Make the curve radius of traveling path as large as
possible
Travel at low speed when traveling around sharp
curves

7) Minimize vibrations for long work cycle or long distance

traveling

Reduce speed to prevent bounce

Transport machines long distances between work-
sites

8) The following guidelines can be effective to minimize

risks of low back pain

Operate the machine only when you are in good

health.
Provide breaks to reduce long periods of sitting in the
same posture
Do not jump down from the cab or machine
Do not repeatedly handle and lift loads

5-5
LIMIT VALUES FOR SLOPES TECHNICAL DATA

LIMIT VALUES FOR SLOPES 0.

Maximum slope angle for machine operation
If operating the machine on a slope, its angle must not exceed
° uphill, downhill or sideways. If you angle the machine at more
than ° during operation, the motor, transmission, hydraulic sys-
tem or axles, will not be supplied with sufficient oil and can be
damaged.

A uphill 25°

B downhill 35°

C sideways 16°

Tipping angle, theoretically

The tipping angle is a calculated value. This states the angle at
which the machine at rest can stand on a slope without tipping
over. You must not work with the machine at these angles as
the motor, transmission, hydraulic system or axles, will not be
supplied with sufficient oil and can be damaged. The specified
angle refers to the transport position. The angle changes if you
raise or lower the work unit.

up hill with operating load 61,9°

A
up hill without operating load 52,4°

down hill with operating load 36,0°

B
down hill without operating load 54,0°

lateral with operating load 40,4°

C
lateral without operating load 41,2°

GK100372

5-6
ATTACHMENTS, OPTIONS
46

WARNING
Please read and make sure that you understand the safety
volume before reading this section.
HANDLING LOAD METER ATTACHMENTS, OPTIONS

HANDLING LOAD METER 0.

GENERAL LOCATIONS 0.
MACHINE MONITOR WITH LOAD METER 0.

(1) Load meter display (2) Character display

The only difference from the machine monitor described in EXPLANATION OF COMPONENTS in the OPERA-
TION section is that the load meter panel is installed in place of the speedometer and meter display pilot lamp.
For details of items not given here, see “MACHINE MONITOR ( 3-6 )“ in the OPERATION section.

6-2
ATTACHMENTS, OPTIONS HANDLING LOAD METER

SWITCHES 0.

(1) Load meter cancel switch (3) Monitor panel mode selector switch 1

(2) Load meter sub total switch (4) Monitor panel mode selector switch 2

For details of switches (3) and (4), see “MONITOR PANEL MODE SELECTOR SWITCH 1 ( 3-40 )“ and “MONI-
TOR PANEL MODE SELECTOR SWITCH 2 ( 3-41 )“.

LOAD METER CANCEL SWITCH 0.

When the measured data is not needed, press the switch at the
top of the bucket control lever.
The data that has just been calculated will be canceled and the
display will return to the display before measuring.

LOAD METER SUB TOTAL SWITCH 0.

Press the switch at the side of the bucket control lever to set
the TOTAL LOADED display (when in addition mode) or
REMAINING TARGET display (when in remain mode) to 0.

6-3
HANDLING LOAD METER ATTACHMENTS, OPTIONS

LOAD METER FUNCTIONS 0.

(1) Addition mode display (4) Bucket load display

(2) Remain mode display (5) Material type display

(3) TOTAL LOADED display (addition mode) or

(6) Speed display or engine speed display
REMAINING TARGET display (remain mode)

Operation of the various functions of the load meter is carried out by using monitor panel mode selector switch 1
or monitor panel mode selector switch 2 on the front switch panel and the load meter cancel switch and load meter
sub total switch on the bucket control lever.

There are the following two types of measurement methods in the load meter mode.

Addition mode (measuring total amount loaded)

This method is useful for measuring the production, such as the amount loaded into the dump truck, the
amount loaded into the hopper, or the total work for half a day. The data can be displayed up to a maximum of
9999 tons for each type of work.
Remain method (measuring amount remaining)
Use this method for work requiring a determined amount (prevention of overloading, mixing of different types of
material, etc.)

LOAD METER ADDITION MODE

For details of the method of switching to the addition mode,
see “SETTING ADDITION MODE ( 6-7 )“.
“TOTAL LOADED“ lights up on load meter display (1).
The bucket load is displayed on load meter display (2), and
the total load is displayed on display (3).

6-4
ATTACHMENTS, OPTIONS HANDLING LOAD METER

If the measured data is not needed, press load meter cancel

switch (4).
The data for the last calculation is canceled and display (3)
returns to the display for the previous measurement.
To return total load display (3) to 0, press load meter sub
total switch (5).

LOAD METER REMAIN MODE

For details of the method of switching to the remain mode,
see “SETTING REMAIN MODE ( 6-9 )“.
“REMAINING TARGET“ lights up on load meter display (1).
The bucket load is displayed on load meter display (2), and
the amount remaining to the target is displayed on display
(3).

If the measured data is not needed, press load meter cancel

switch (4).
The data for the last calculation is canceled and display (3)
returns to the display for the previous measurement.
To return total load display (3) to 0, press load meter sub
total switch (5).

SELECTION OF DISPLAY FOR TYPE OF LOAD

For details of the method of selecting the type of load, see
“SETTING ADDITION MODE ( 6-7 )“ and “SETTING
REMAIN MODE ( 6-9 )“.
It is possible to make categories for a maximum of five
types of material for TOTAL LOADED or REMAINING TAR-
GET.
If the settings for types A to E are changed for each type of
material when operations are carried out, it is possible to
store in memory the data for TOTAL LOADED or REMAIN-
ING TARGET for each type of material.
One of the selected types of material A to E is displayed on
load meter display (1).

METHOD OF CALIBRATION (ADJUSTING 0 POINT)

For details of the method of carrying out calibration, see “CARRYING OUT CALIBRATION (ADJUSTING 0
POINT) WHEN EMPTY ( 6-15 )“ and “CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN
LOADED ( 6-17 )“.

REMARK
Normally, it is sufficient to carry out calibration only when empty, but it is also possible to carry out cali-
bration when loaded if necessary.

6-5
HANDLING LOAD METER ATTACHMENTS, OPTIONS

DELETING LOAD METER DISPLAY

It is possible to set so that there is no load meter display.
If there is no display, only the speed is displayed.
To switch the load meter between display and no display, see “STOPPING CALCULATION ( 6-14 )“.

SPEED DISPLAY
The travel speed of the machine is displayed on load meter
display (1).

It is also possible to switch this display (1) so that it displays the

engine speed.
If you wish to switch the speed display to the engine speed dis-
play, please ask your Komatsu distributor to carry out the oper-
ation.

6-6
ATTACHMENTS, OPTIONS HANDLING LOAD METER

HANDLING LOAD METER DISPLAY 0.

SETTING ADDITION MODE 0.
1. Check that the normal service meter and time are displayed
on the character display.

2. Press the (‘) of monitor panel selector switch 1 and display

“LOAD METER“.

3. Press the (‘) of monitor panel selector switch 1 and display

“ADDITION MODE“.

REMARK
If the previous setting was the addition mode, “ADDITION
MODE“ is displayed; if the previous setting was the remain
mode, “REMAINS MODE“ is displayed.

4. If the display is “REMAINS MODE“, press the (>) or (<) of

monitor panel mode selector switch 2 to display “ADDITION
MODE“.

6-7
HANDLING LOAD METER ATTACHMENTS, OPTIONS

5. Press the (‘) of monitor panel selector switch 1 and display

“MATERIAL < > SELECT“.

6. Check the display for the selected material on load meter

display (1).
The present selection display is A.
In the case of the addition mode, “TOTAL LOADED“ is dis-
played on display (2).
7. If A is to remain selected, press the („) of monitor panel
mode selector switch 1. A is then selected.
If A is to be changed to B to E, press the (>) or (<) of moni-
tor panel mode selector switch 2 to select the type of mate-
rial, then press the („) of monitor panel mode selector
switch 1.
8. This completes the setting of the addition mode.
The character display returns to the normal service meter
and time display.

Once the setting has been made, even if the starting switch
is turned OFF and operations are stopped, the setting is
retained. When operations are started again, there is no
need to carry out the setting again. All further loads will be
added to the total load recorded before operations were
stopped.

6-8
ATTACHMENTS, OPTIONS HANDLING LOAD METER

SETTING REMAIN MODE 0.

When carrying out operations in the remain mode, set to the remain mode. For details of the remain mode func-
tions, see “SUBTRACTION FUNCTION ( 6-20 )“.
1. Check that the normal service meter and time are displayed
on the character display.

2. Press the (‘) of monitor panel selector switch 1 and display

“LOAD METER“.

3. Press the (‘) of monitor panel selector switch 1 and display

“REMAINS MODE“.

REMARK
If the previous setting was the addition mode, “ADDITION
MODE“ is displayed; if the previous setting was the remain
mode, “REMAINS MODE“ is displayed.

4. If the display is “ADDITION MODE“, press the (>) or (<) of

monitor panel mode selector switch 2 to display “REMAIN
MODE“.

6-9
HANDLING LOAD METER ATTACHMENTS, OPTIONS

5. Press the (‘) of monitor panel selector switch 1 and display

“INPUT TARGET“.
6. Input the target load.
Before the target is input, “000.0 t“ is displayed on the target
line and the cursor is at the 100 ton position.

The following explanation explains the procedure when

inputting 30 tons as the target.

7. “0“ is marked by the cursor at the 100 ton position, so leave it at “0“ and press the (‘) of monitor panel selector
switch 1.
“0“ is selected and the cursor moves to the 10 ton position.
8. The “0“ at the 10 ton position must be changed to “3“, so
press the (>) or (<) of monitor panel mode selector switch 2
to change to “3“, then press the (‘) of monitor panel selec-
tor switch 1.
“3“ is selected and the cursor moves to the 1 ton position.
9. “0“ is already displayed at both the 1 ton and 0.1 ton posi-
tions, so press the (‘) of monitor panel selector switch 1
twice.
“0.0“ is selected and 30 tons is set as the target load.

REMARK
If 0 tons is input as the target load, it is not accepted. The buzzer gives a long sound and the mode
changes to give the addition mode display.

10.Press the (‘) of monitor panel selector switch 1. If the

monitor accepts the input amount, the buzzer will give short
sounds and “MATERIAL < > SELECT“ is displayed.

11. Check the display for the selected material on load meter
display (1).
The present selection display is B.
In the remain mode, “REMAINING TARGET“ is displayed
on display (2).
12.If B is to remain selected, press the („) of monitor panel
mode selector switch 1. B is then selected.
If B is to be changed to A, C, D or E, press the (>) or (<) of
monitor panel mode selector switch 2 to select the type of
material, then press the („) of monitor panel mode selector
switch 1.

6-10
ATTACHMENTS, OPTIONS HANDLING LOAD METER

13.This completes the setting of the remain mode.

The character display returns to the normal service meter
and time display.

Once the setting has been made, even if the starting switch
is turned OFF and operations are stopped, the setting is
retained. When operations are started again, there is no
need to carry out the setting again. All further loads will be
subtracted from the total load recorded before operations
were stopped.

6-11
HANDLING LOAD METER ATTACHMENTS, OPTIONS

TOTAL LOAD DATA DISPLAY 0.

1. Check that the normal service meter and time are displayed
on the character display.

2. Press the (‘) of monitor panel selector switch 1 and display

“LOAD METER“.

3. Press the (‘) of monitor panel selector switch 1, then press

the (>) or (<) of monitor panel mode selector switch 2 to dis-
play “DATA“.

4. Press the (‘) of monitor panel selector switch 1 to display

“TOTAL DATA“.
The time when the load on the bottom line was calculated is
displayed as the hour meter standard.
5. Press the (>) or (<) of monitor panel mode selector switch 2
to select the data for each of A to E or the all lighted-up dis-
play.

The total load data for each of A to E and for all data is dis-
played on the load meter display.
Check the material selection display on load meter display (1).
In the example on the right, all of A to E for all data selected
light up.
On display (2) the total load data for all data or individual total
load data for A to E is displayed.
On display (3) the individual number of loads for A to E is dis-
played.
The total value can be cleared as follows.
1) Press the (>) or (<) of monitor panel mode selector
switch 2, and select the individual items to be cleared
from A to E or select the all lighted-up display.

6-12
ATTACHMENTS, OPTIONS HANDLING LOAD METER

2) Press the (‘) of monitor panel selector switch 1 to dis-

play “RESET“.
3) “YES < > NO“ is displayed, and the cursor is at the NO
position, so press the(<) of monitor panel mode selector
switch 2 to move the cursor to the “Y“ of YES.

4) Press the („) of monitor panel mode selector switch 1.

The selected individual item from A to E or all the data is
cleared.
If the monitor accepts the clear command, the buzzer
gives short sounds and the display returns to the normal
service meter and time display.

6-13
HANDLING LOAD METER ATTACHMENTS, OPTIONS

STOPPING CALCULATION 0.
1. Check that the normal service meter and time are displayed
on the character display.

2. Press the (‘) of monitor panel selector switch 1 and display

“LOAD METER“.

3. Press the (‘) of monitor panel selector switch 1, then press

the (>) or (<) of monitor panel mode selector switch 2 and
select “OFF“ on the bottom line.

4. Press the (‘) of monitor panel selector switch 1. The load

meter display goes out and the screen switches to the
speed display. In addition, the character display returns to
the normal service meter and time display.
5. When starting the calculation again, set to the addition
mode or remain mode. For details, see “SETTING ADDI-
TION MODE ( 6-7 )“ or “SETTING REMAIN MODE ( 6-9 )“.

6-14
ATTACHMENTS, OPTIONS HANDLING LOAD METER

CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY 0.

1. Check that the normal service meter and time are displayed
on the character display.

2. Press the (‘) of monitor panel selector switch 1 and display

“LOAD METER“.

3. Press the (‘) of monitor panel selector switch 1, then press

the (>) or (<) of monitor panel mode selector switch 2 and
select “CALIBRATION“.

4. Press the (‘) of monitor panel selector switch 1. “EMPTY

BUCKET“ is displayed on the bottom line.

5. Press the (‘) of monitor panel selector switch 1. The dis-

play changes to “STEP 1“ on the top line, and “FULLY
ROLL BACK“ and “AT CARRY POSI“ are displayed in turn
for 3 seconds each on the bottom line.
6. Follow the instructions on the screen, tilt the empty bucket
back fully, then lower the lift arm to set to the travel posture.

6-15
HANDLING LOAD METER ATTACHMENTS, OPTIONS

7. When the lift arm is lowered, the display changes to “STEP

2“ and “RAISE TO TOP“.
This completes preparation for setting the calibration when
empty.
8. Follow the instructions on the screen and raise the lift arm
fully.
When raising the lift arm, carry out the operation as close to
actual operation as possible.

9. When the setting of the empty calibration is completed cor-

rectly, the buzzer gives short sounds, and the character dis-
play returns to the normal service meter and time display.

10.If the setting of the empty calibration is not completed cor-

rectly, the buzzer gives a long sound, and the display
returns to “CALIBRATION“ on the top line and “EMPTY
BUCKET“ on the bottom line.
11. Repeat the procedure again from Step 5.

6-16
ATTACHMENTS, OPTIONS HANDLING LOAD METER

CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED 0.

REMARK
Normally, there is no need to carry out calibration when loaded. It is enough to carry out calibration when
empty, so carry out calibration when loaded only if greater accuracy is required.

1. Check that the normal service meter and time are displayed
on the character display.

2. Press the (‘) of monitor panel selector switch 1 and display

“LOAD METER“.

3. Press the (‘) of monitor panel selector switch 1, then press

the (>) or (<) of monitor panel mode selector switch 2 and
select “CALIBRATION“.

4. Press the (‘) of monitor panel selector switch 1. “EMPTY

BUCKET“ is displayed on the bottom line.

6-17
HANDLING LOAD METER ATTACHMENTS, OPTIONS

5. Press the (>) of monitor panel mode selector switch 2. The

bottom line changes to “LOAD BUCKET“, so press the (‘)
of monitor panel selector switch 1.

6. Press the (‘) of monitor panel selector switch 1. The dis-

play changes to “STEP 1“ on the top line, and “FULLY
ROLL BACK“ and “AT CARRY POSI“ are displayed in turn
for 3 seconds each on the bottom line.
7. Load the bucket with a load of a known amount, then follow
the instructions on the screen, tilt the bucket back fully, and
lower the lift arm to set to the travel posture.

8. When the lift arm is lowered, the display changes to “STEP

2“ and “RAISE TO TOP“.
This completes preparation for setting the calibration when
loaded.
9. Follow the instructions on the screen and raise the lift arm
fully.
When raising the lift arm, carry out the operation as close to
actual operation as possible.
10.When the setting of the loaded calibration is completed cor-
rectly, the buzzer gives short sounds, and the screen
changes to the screen for inputting the target load.
11. If the setting of the loaded calibration is not completed cor-
rectly, the buzzer gives a long sound, and the display
returns to “CALIBRATION“ on the top line and “LOAD
BUCKET“ on the bottom line.
12.Repeat the procedure again from Step 6.

6-18
ATTACHMENTS, OPTIONS HANDLING LOAD METER

13.IInput the load on the target load input screen.

The data for the previously calculated load is displayed on
the input screen.
The cursor is at the 100 ton position.

The following explanation explains the procedure when

inputting 7.5 tons as the target when the previous load (the
load set in Step 7) is 7.1 tons.

“0“ is displayed at the 100 ton position, so leave it at “0“ and

press the (‘) of monitor panel selector switch 1 twice.
“00“ is selected and the cursor moves to the 1 ton position.
14.“7“ is already displayed at the 1 ton position, so press the
(‘) of monitor panel mode selector switch 1.
“7“ is selected and the cursor moves to the 0.1 ton position.
15.“1“ is displayed at the 0.1 ton position, so press the (>) or
(<) of monitor panel selector switch 2 to select “5“, then
press the (‘) of monitor panel mode selector switch 1.
“.5“ is selected and 7.5 tons is set as the target load.

16.Press the (‘) of monitor panel mode selector switch 1. If

the monitor accepts the setting, the buzzer gives short
sounds, and the setting of the loaded calibration is com-
pleted. The screen returns to the normal service meter and
time display.

6-19
HANDLING LOAD METER ATTACHMENTS, OPTIONS

SUBTRACTION FUNCTION 0.
The following explanation assumes that after setting the remain
mode, the target load is 12 tons as shown in the diagram on
the right and that B is selected as the type of material.

1. This is the first load.

The result of measuring the load in the bucket is 5.1 tons.
12.0 - 5.1 = 6.9, so the next target load is displayed as 6.9
tons.

2. When 15 seconds pass after measuring, the bucket load is

deleted and the load is displayed as 0.0 tons.

3. This is the second load.

The load in the bucket is 4.9 tons.
6.9 -4.9 = 2.0 tons, so the next target load is displayed as
2.0 tons.

4. This is the third load.

The result of measuring the load in the bucket is 5.0 tons.
This is 3.0 tons over the target amount, so -3.0 tons is dis-
played.

6-20
ATTACHMENTS, OPTIONS HANDLING LOAD METER

5. The target load is displayed as -3.0 tons, and after 3 sec-

onds, the display changes to the display shown on the right.
The target value of 2.0 tons is the target load after complet-
ing the loading of the second bucket.
6. Load the target of 2.0 tons from the 5.0 tons loaded in the
bucket.
7. After loading, lower the lift arm and then raise it again in
order to weigh the amount remaining in the bucket. The
amount remaining in the bucket is weighed and displayed.

The amount remaining in the bucket is 3.5 tons.

The target load is 2.0 - (5.0 - 3.5) = 0.5 tons
The next target load of 0.5 tons is displayed.

8. Load the target of 0.5 tons from the 3.5 tons loaded in the
bucket.
9. After loading, lower the lift arm and then raise it again in
order to weigh the amount remaining in the bucket. The
amount remaining in the bucket is weighed and displayed.

10.The amount remaining in the bucket is 3.1 tons.

The target load is 0.5 - (3.5 - 3.1) = 0.1 tons

11.To start the next loading operation, press the load meter
subtotal switch and the first loading operation is completed.

12.At this point, the amount remaining in the bucket (3.1 tons)
is subtracted from the target load for the next loading opera-
tion, and the result (8.9 tons) is displayed as the target load.

The amount remaining in the bucket is 3.1 tons.

12.0 - 3.1 = 8.9 tons, so 8.9 tons is displayed as the next
target load.

6-21
HANDLING LOAD METER ATTACHMENTS, OPTIONS

13.If the second loading operation is to be carried out without

using the load remaining in the bucket, press the load meter
cancel switch. The target load will return to the initial setting
(12 tons).
The target load is displayed as 12.0 tons.

METHOD OF SETTING TIME ON CLOCK 0.

(The time display is only available on machines equipped with the load meter)
1. Check that the normal service meter and time are displayed
on the character display.

2. Press the (‘) of monitor panel selector switch 1 and display

“LOAD METER“.

3. Press the (‘) of monitor panel mode selector switch 1, then

press the (>) or (<) of monitor panel mode selector switch 2
to select “DAY & TIME ADJUST“.

6-22
ATTACHMENTS, OPTIONS HANDLING LOAD METER

4. Press the (‘) of monitor panel mode selector switch 1.

The top line displays “ADJUST 23: 59“.
The bottom line displays “2000/01/01“.

REMARK
Once the time is input, the clock will show the correct time
from that time on.

5. Input the day and time.

The cursor is displayed at each input item in the following order: Year, Month, Day, Hour, Minute.
Use the (>) or (<) of monitor panel mode selector switch 2 to move the numbers up or down and input numbers
between 0 and 9 at the cursor position.
6. After inputting the number, press the (‘) of monitor panel mode selector switch 1 to select and move the cur-
sor to the next input position.
Repeat Steps 5 and 6 to input and select the numbers from the year to the minute.
7. When the (‘) of monitor panel mode selector switch 1 is
pressed to select the last digit of the minutes, the character
display will return to the normal service meter and time dis-
play.
8. To stop the input operation midway, or if the input is mis-
taken, press the („) of monitor panel mode selector switch
1 to go back to the previous display.

6-23
HANDLING LOAD METER ATTACHMENTS, OPTIONS

PRINTER OUTPUT 0.
PRINTOUT MODE 0.
(This functions only when the optional printer is installed.)

Three types of output mode (A, B, C) can be selected for the load meter printout.
For details, see “METHOD OF SELECTING PRINTOUT MODE ( 6-25 )“.

A mode: Printout of totals

The number of loads and total amount loaded for each type of material are printed out.
B mode: Printout of subtotals
The total for each load, number of loads, and total amount loaded for each type of material are printed out.
C mode: Printout of operating record
In addition to the items printed out in A mode, the maintenance items and time remaining until maintenance are
also printed out.

The printouts shown below are examples of the load meter printouts for the WA380.

6-24
ATTACHMENTS, OPTIONS HANDLING LOAD METER

METHOD OF SELECTING PRINTOUT MODE 0.

(This functions only when the optional printer is installed.)

1. Check that the normal service meter and time are displayed
on the character display.

2. Press the (‘) of monitor panel selector switch 1 and display

“LOAD METER“.

3. Press the (‘) of monitor panel mode selector switch 1, then

press the (>) or (<) of monitor panel mode selector switch 2
to select “PRINT TYPE“.

4. Press the (‘) of monitor panel mode selector switch 1.

The bottom line will change to display the printout mode “A
< > B < > C“.
5. Press the (>) or (<) of monitor panel mode selector switch 2
to set to the desired printout mode.

Three types of output mode (A, B, C) can be selected for

the load meter printout.
For details, see “PRINTOUT MODE ( 6-24 )“.
6. After setting the printout mode, press the („) of monitor
panel mode selector switch 1.
If the monitor accepts it, the buzzer will give short sounds
and the screen will return to the load meter display.

6-25
HANDLING LOAD METER ATTACHMENTS, OPTIONS

7. To print out in A or B mode, keep the load meter sub total

switch pressed for at least 2 seconds and the data will be
printed out.

When printing out in C mode, the data will be printed out

immediately when C mode is selected in Step 5.
When the C mode printout is finished, the printout mode
setting will return to A or B.

8. To stop the input operation midway, or if the input is mis-

taken, press the („) of monitor panel mode selector switch
1 to go back to the previous display.

6-26
ATTACHMENTS, OPTIONS HANDLING TORQUE CONVERTER LOCK-UP

HANDLING TORQUE CONVERTER LOCK-UP 0.

WARNING
When traveling down slopes of a grade of more than 6°, never depress the accelerator pedal fully, regard-
less of whether the torque converter lock-up switch is ON or OFF. It is extremely dangerous to drive too
fast.

NOTICE
To prevent overrunning when traveling at high speed in the following cases, do not shift down gear.
When traveling in F3 at a speed of more than 25 km/h, do not shift down to F2.
When traveling in F4 at a speed of more than 36 km/h, do not shift down to F3.

When the actual speed range is 3rd or 4th in either FORWARD or REVERSE, the torque converter lock-up func-
tion is actuated according to the travel speed and sets to direct drive.
To prevent overrun, the lock-up is automatically canceled to prevent the travel speed from going above 40 km/h.

GENERAL LOCATIONS 0.

(1) Torque converter lock-up switch (3) Shift indicator (displays actual speed range)

(2) Torque converter lock-up pilot lamp (4) Character display

TORQUE CONVERTER LOCK-UP SWITCH

This switch (1) is the control switch for the torque converter
lock-up function.
Position (a): ON
The pilot lamp inside the switch lights up and the lock-up is
actuated according to the travel speed. While the lock-up is
engaged, the lock-up pilot lamp on the machine monitor
lights up.
Position (b): OFF
The lock-up does not function.

6-27
HANDLING TORQUE CONVERTER LOCK-UP ATTACHMENTS, OPTIONS

TORQUE CONVERTER LOCK-UP PILOT LAMP

This monitor (2) lights up when the torque converter lock-up is
engaged and the transmission actually enters direct drive.

For details of (3) and (4), see “SHIFT INDICATOR ( 3-26 )“ and
“ACTION CODE DISPLAY ( 3-9 )“ in the section on the
machine monitor in the OPERATION section.

METHOD OF OPERATION 0.
1. Press the top (a) of the torque converter lock-up switch to
turn it ON.
The pilot lamp inside the switch lights up.
2. When the actual speed range is 3rd or 4th in either FOR-
WARD or REVERSE, the torque converter lock-up function
is actuated according to the travel speed and sets to direct
drive.

REMARK
When 4th is selected in auto-shift mode, the lock-up is not
actuated in 3rd. The lock-up is actuated only in the
selected 4th gear.

When the lock-up is actually actuated, the lock-up pilot lamp on

the machine monitor lights up.

3. To cancel the lock-up, press the bottom (b) of the torque

converter lock-up switch to turn it OFF.
The lock-up is canceled.

The travel speed for actuation and cancellation of the lock-up is as shown below.

Lock-up FORWARD travel speed REVERSE travel speed

(km/h) (km/h)

Speed range Actuated Canceled Actuated Canceled

3rd 11 to 14 10 to 12 16 13

4th 21 to 24 19 22 to 25 20

6-28
ATTACHMENTS, OPTIONS HANDLING TORQUE CONVERTER LOCK-UP

WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED 0.

TRAVEL SPEED WARNING FUNCTION
(This functions even when the torque converter lock-up switch is OFF.)

When the travel speed goes above 38.0 km/h, the central warning lamp lights up and the alarm buzzer sounds.
At the same time, “E00 OVERRUN PROTECT“ is displayed on the character display.
If the alarm buzzer sounds, depress the brake immediately to slow the machine down.
When the travel speed goes below 36.0 km/h, the alarm buzzer stops.

TRAVEL SPEED LIMIT FUNCTION

(This functions only when the torque converter lock-up switch is ON.)

To prevent the travel speed from going above 40.0 km/h, the lock-up is automatically canceled.
The lock-up cancel continues until the travel speed goes below 38.0 km/h.

6-29
HANDLING AUTOMATIC AIR-CONDITIONER ATTACHMENTS, OPTIONS

HANDLING AUTOMATIC AIR-CONDITIONER 0.

By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it pos-
sible to provide a pleasant working environment even on dusty jobsites.

GENERAL LOCATIONS AND FUNCTIONS OF CONTROL PANEL 0.

DEF DEF

DEF DEF

FACE FACE

FOOT

(1) OFF switch (5) Auto switch

(2) Fan switch (6) RECIRC/FRESH selector switch

(3) Temperature control switch (7) Monitor panel

(4) Mode selector switch (8) Air conditioner switch

Even when the starting switch is turned OFF, the mode settings are retained in memory.

OFF SWITCH 0.
This switch (1) turns the fan OFF.
When OFF switch (1) is pressed, the set temperature and
air flow displays on machine monitor (7) and the lamp at the
top of auto switch (5) go out.

6-30
ATTACHMENTS, OPTIONS HANDLING AUTOMATIC AIR-CONDITIONER

FAN SWITCH 0.
This switch (2) is used to adjust the air flow.
The air flow can be adjusted to six levels.
Press the ∧ switch to increase the air flow; press the ∨
switch to reduce the air flow.
When the fan switch is pressed, the lamp at the top of the
auto switch goes out.
During auto operation, the air flow is automatically adjusted.

Monitor display and air flow 0.

Liquid crystal
Air flow
display

Air flow "low"

Air flow "medium 1"

Air flow "medium 2"

Air flow "medium 3"

Air flow "medium 4"

Air flow "high"

6-31
HANDLING AUTOMATIC AIR-CONDITIONER ATTACHMENTS, OPTIONS

TEMPERATURE CONTROL SWITCH 0.

This switch (3) is used to control the temperature inside the
cab. The temperature can be set between 18°C and 30°C .
Press the ∧ switch to raise the set temperature; press the ∨
switch to lower the set temperature.
The temperature is generally set at 25°C.
The temperature can be set in stages of 0.5°C.

<Monitor display and the function>

Monitor display (°C) Set temperature

18.0 Max. cooling

Adjusts temperature inside cab to set

18.5 to 31.5
temperature

32.0 Max. heating

MODE SELECTOR SWITCH 0.

This switch (4) is used to select the vents.
The vent position can be selected from five modes: FACE,
FACE/FOOT, FOOT, FOOT/DEF, DEF.
When this switch (4) is pressed, the display on monitor
panel (7) changes in turn, and the air blows out from the
vents shown in the display.
During automatic operation, the vents are automatically
selected.

AUTO SWITCH 0.
With this switch (5), the air flow, vents, and air source
(RECIRC/FRESH) are automatically selected according to the
set temperature.
This switch also acts as the air conditioner main switch.
When auto switch (5) is pressed, the lamp at the top of the
auto switch lights up and the auto mode is displayed.
When the fan switch is pressed, the lamp at the top of the
auto switch goes out.
Normally, press this switch, then use temperature control
switch (3) to set the temperature, and run the air conditioner
under automatic control.
When the control is switched from automatic operation to
manual operation, it is possible to operate the switch to
change the air flow, vents, and air source (RECIRC/
FRESH). When the manual control is used, the lamp at the
top of the auto switch goes out.

6-32
ATTACHMENTS, OPTIONS HANDLING AUTOMATIC AIR-CONDITIONER

RECIRC/FRESH SELECTOR SWITCH 0.

This switch (6) is used to switch the air source between recircu-
lation of the air inside the cab and intake of air from the outside.
When switch (6) is pressed, the lamp at the top of the selec-
tor switch lights up to show that air is being blown out.
During automatic operation, the selection of inside air
(RECIRC) and outside air (FRESH) is carried out automati-
cally.

RECIRC The outside air is shut off and only the air inside the cab is circulated.
Use this position to carry out rapid cooling of the cab or when the out-
side air is dirty.

FRESH Outside air is taken into the cab.

Use this position to take in fresh air or when carrying out demisting.

MONITOR PANEL 0.
The monitor panel shows the temperature setting (a), air flow
(b), and vent selection (c).

AIR CONDITIONER SWITCH 0.

This switch (8) is used to turn the air conditioner (cooling,
dehumidifying, heating) ON or OFF.
When the auto switch or fan switch is turned ON and air
conditioner switch (8) is pressed, the air conditioner is
switched ON, the lamp at the top of the air conditioner
switch lights up, and the air conditioner starts. When it is
pressed again to the OFF position, the lamp at the top of the
air conditioner switch goes out.
The air conditioner cannot be operated while the fan is
stopped.

6-33
HANDLING AUTOMATIC AIR-CONDITIONER ATTACHMENTS, OPTIONS

METHOD OF OPERATION 0.
The air conditioner can be operated automatically or manually. Select the method of operation as desired.

AUTOMATIC OPERATION 0.
1. Turn auto switch (5) ON.
The lamp at the top of switch (5) lights up.
The set temperature (a) and air flow (b) are displayed on
the monitor.

2. Operate temperature control switch (3) to set to the desired

temperature. The air flow, vents, and air source (RECIRC/
FRESH) are selected automatically and the air conditioner
is run automatically to bring the temperature to the set tem-
perature.

STOPPING AUTOMATIC OPERATION 0.

Press OFF switch (1). The display of the set temperature (a)
and air flow (b) on the monitor panel, and the lamps at the top
of auto switch (5) and air conditioner switch (8) go out, and the
air conditioner stops.

6-34
ATTACHMENTS, OPTIONS HANDLING AUTOMATIC AIR-CONDITIONER

MANUAL OPERATION 0.
1. Press fan switch (2) and select the air flow. Check that the
set temperature (a) and air flow (b) are displayed on the
monitor panel.

2. Turn air conditioner switch (8) ON. Check that the lamp at
the top of the air conditioner switch lights up.

3. Press temperature control switch (3) to set the temperature

inside the cab.

6-35
HANDLING AUTOMATIC AIR-CONDITIONER ATTACHMENTS, OPTIONS

4. Press mode selector switch (4) and select the desired vent.
The display of the vent selection (c) on the monitor panel
will change according to the selection.

5. Press RECIRC/FRESH selector switch (6) and select recir-

culation of the air inside the cab (RECIRC) or intake of fresh
air from outside (FRESH).

STOPPING MANUAL OPERATION 0.

Press OFF switch (1). The display of the set temperature (a)
and air flow (b) on the monitor panel, and the lamps at the top
of auto switch (5) and air conditioner switch (8) go out, and the
air conditioner stops.

PRECAUTIONS WHEN USING 0.

For the precautions when using the air conditioner, see “PRECAUTIONS WHEN USING ( 3-63 )“ in the section on
the air conditioner in the OPERATION section.

INSPECTION AND MAINTENANCE 0.

When carrying out inspection and maintenance of a machine equipped with air conditioner, see “MAINTENANCE
SCHEDULE CHART ( 4-15 )“.

6-36
ATTACHMENTS, OPTIONS CENTRAL LUBRICATION

CENTRAL LUBRICATION 0.

OPERATION 0.
Turn the starting switch ON.

OPERATION AS DESIRED
If auto-greasing switch (1) on the right switch panel or the start
button of the lubrication controller inside the box under the step
on the left side of the machine are pressed, one cycle of greas-
ing will be carried out regardless of the hours of operation.
The time count for the greasing interval will be canceled, and
when the electric pump automatically stops, the count will start
again.

PILOT LAMP DISPLAY ON MACHINE MONITOR

The display of pilot lamp (2) on the machine monitor lights up

or flashes according to the following conditions.

Lighted up: Normal operation

1 flash per sec: Grease cartridge empty
2 flashes per sec: Defective decompression

The settings when shipping from factory are as follows:

Greasing interval: after 1 hour
Greasing time: 10 minutes.

6-37
CENTRAL LUBRICATION ATTACHMENTS, OPTIONS

DISPLAY AND CONTROL UNIT 0.

The display and control unit is protected by a transparent
plastic cover against splashing water and mechanical damage.
For programming, the cover has to be dismounted and,
following programming, reattached with a screwdriver.

LED-DISPLAY 0.
1. Seven-segment display: Values and operating state

2. Pause time (PAUSE h/lmp)

1
3. Pump operation (CONTACT min/lmp) PAUSE
2 h/lmp
4. Monitoring of system function by means of an external cycle CONTACT
switch (CS) 3 min/ lmp

5. Monitoring of system function by means of an external 4

pressure switch (PS) CS

6. Fault message (FAULT) 5

PS

6
FAULT

PUSHBUTTONS 0.
1. Turn on display
Display values and parameters
Set values and parameters

2. Change between programming and display mode

Confirm values (SET)

3. Activate intermediate lubrication

Clear fault message (DK)

6-38
ATTACHMENTS, OPTIONS CENTRAL LUBRICATION

CHANGING THE LUBRICATION INTERVAL TIMES 0.

The settings when shipping from factory are as follows:
Greasing interval: after 1 hour
Greasing time: 10 minutes.

Step Key Display

1 000 in display flashes

Press for more than 2s

2 Automatically indicates first parameter

Example: „Pause in timer operation“
Press briefly LED „Pause“ flashes
(confirm code)
3 Pause time 1 h

Press briefly

4 Set new value

Example: 6.8 h = 6 h 48 min

5 Indicates next parameter

„Pump running time in timer mode“
Press briefly LED „Contact“ flashes
(confirm new value)
6 Pump running time 4 min

Press briefly

7 Set new value

Example: 3 min

8 Press briefly Confirm new value

9 Press for Changes are written to the memory, and the LED indicators
more than 2s extinguish.

6-39
HANDLING MULTIFUNCTION LEVER ATTACHMENTS, OPTIONS

HANDLING MULTIFUNCTION LEVER 0.

EXPLANATION OF COMPONENTS 0.

4
5

(1) Multifunction lever (4) Directional selector pilot lamp

(2) Directional selector switch (5) Directional lever

(3) Directional selector switch actuation switch

6-40
ATTACHMENTS, OPTIONS HANDLING MULTIFUNCTION LEVER

WORK EQUIPMENT LEVER 6

Use this lever (1) to operate the lift arm and bucket.

NOTICE
Do not use the FLOAT position when lowering the bucket.
Use the FLOAT position when leveling, see “LEVELING
OPERATIONS ( 3-99 )“.

Position (a): RAISE

When the multifunction lever is pulled over the LIFT position,

the lever remains in this position until the boom has reached
the preset self-trigger position and the lever is brought to the
HOLD position. Raise

Position (b): HOLD

The lift arm and bucket stop and remain in the same position.

Position (c): LOWER Lower

Position (d): FLOAT AE41484B-A

The lift arm moves freely under external force.

Position (e): TILT

When the multifunction lever is pulled over the TILT position, it Tilt
remains in this position until the shovel has reached the posi-
tion preset with the positioner. The lever then returns to the
HOLD position. Dump

Position (f): DUMP

AE41485B-A

6-41
HANDLING MULTIFUNCTION LEVER ATTACHMENTS, OPTIONS

DIRECTIONAL SELECTOR SWITCH 6

This switch (2) is used to switch the direction of travel of the
machine between forward and reverse.

F Position: FORWARD

N Position: NEUTRAL
R Position: REVERSE

Before operating this switch, check that the condition is as fol-

lows.

Directional lever is at N
Directional selector switch actuation switch is at ON

If the condition is not as above, the switch will not work.

For details, see “USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE ( 6-44 )“.

REMARK
When directional selector switch actuation switch (3) is ON, if drive directional lever (5) is not at the N position and
directional selector switch (2) is also not at the N position, the engine will not start.

DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH 6

When this switch (3) is turned on, the directional selector

switch is actuated.

Position (a): ON

The directional selector switch is actuated.

Position (b): OFF

The directional selector switch is turned off.

6-42
ATTACHMENTS, OPTIONS HANDLING MULTIFUNCTION LEVER

DIRECTIONAL SELECTOR PILOT LAMP 6

This lamp (4) displays the position of the directional selector
switch under the following conditions.
Directional selector switch operation switch: ON position
Directional lever: N position

F lights up: FORWARD

N lights up: NEUTRAL

R lights up: REVERSE

REMARK
Directional lever: Neutral position
Directional selector actuation switch (3): ON position
Directional selector switch (2): Forward or Reverse posi-
tion

When the starting switch is turned to the ON position with

the levers and switches in the following condition, all
directional lever positional pilot lamps (4) will go out.
If directional selector switch (2) is then set to the N posi-
tion, directional lever positional pilot lamps (4) display the
normal condition “N“.

6-43
HANDLING MULTIFUNCTION LEVER ATTACHMENTS, OPTIONS

OPERATION 6

USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE 6

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.
When switching between FORWARD and REVERSE,
depress the brake to reduce the travel speed suffi-
c i e n t l y, t h e n c h a n g e t h e d i r e c t i o n o f t r a v e l .
(Max.speed for changing direction: 13 km/h (8.1 MPH))
When the directional selector switch actuation switch
(3) is at the ON position, if the directional lever (1) is
operated to FORWARD or REVERSE, the machine will
travel in forward or reverse according to the operation
of the directional lever, regardless of the position of
the directional selector switch (2).
Priority is given to the operation of the directional
lever, so be careful when operating.

1. Place the directional lever (1) at the N position.

2. Place the directional selector switch (2) at the N position.

6-44
ATTACHMENTS, OPTIONS HANDLING MULTIFUNCTION LEVER

3. Place the directional selector switch actuation switch (3) at

the ON position (a).

4. Place the directional selector switch (2) at the F (forward) or

R (reverse) position.

REMARK
When the directional selector switch actuation switch (3)
is at the ON position, if the drive directional lever (5) is oper-
ated to FORWARD or REVERSE, the machine will travel in
forward or reverse according to the operation of the direc-
tional lever, regardless of the position of the directional
selector switch (2).
Priority is given to the operation of the directional lever.
When using directional selector switch (2) again, set drive
directional lever (5) and directional selector switch (2) to the
N position.

6-45
HANDLING MULTIFUNCTION LEVER ATTACHMENTS, OPTIONS

KICKDOWN SWITCH 0.
When the gearshift lever is in second gear, the gear unit
switches down to first gear when the switch (1) on the multi-
function lever is pressed.

If the transmission is in auto-shift, and the travel speed is below

12.5 km/h in any speed range when traveling in either forward
or in reverse, the kick-down switch is actuated and it is possible
to shift down to 1st. This makes it easy to carry out load and
carry operations. Even if the travel speed is more than 12.5 km/
h, this switch can be used to shift the transmission down. Each 1
time the kick-down switch is pressed, the speed range will shift
down one range at a time (F4 -> F3 -> F2).
When the torque converter is in the lock-up condition (option), the lock-up is canceled.

REMARK
When canceling the kick-down, operate the directional lever. In manual shift, the kick-down can be can-
celed by operating the gearshift lever to any position other than 2nd. It is also possible to cancel the
kick-down by turning the starting switch OFF.
In auto-shift, if the travel speed becomes high after the kick-down, the gear will be shifted up by the
auto-shift.
In auto-shift, when traveling at more than 25 km/h in 3rd or at more than 35 km/h in 4th, even if the kick-down
switch is pressed, the transmission will not shift down. This is to prevent overrun of the engine.

HOLD SWITCH 0.
Activate the switch (2) on the multifunction lever in order to set
the speed range for drives with automatic gear shift.
The transmission will be fixed in the speed range displayed on 2
shift indicator (A) on the machine monitor and shift hold pilot
lamp (B) will light up.
When the switch is pressed again, the display goes out.
Use this function to select the desired speed range when trav-
eling up or down hills or when carrying out operations such as
grading.

REMARK
When the torque converter is in the lock-up condition
(option), the transmission cannot be fixed.
When canceling the shift hold, operate the directional
lever or gearshift lever or operate the transmission shift
mode selector switch to MANUAL. It is also possible to
cancel the hold shift by turning the starting switch OFF.

6-46
ATTACHMENTS, OPTIONS JOYSTICK STEERING SYSTEM

JOYSTICK STEERING SYSTEM 0.

To enable you to use the joystick steering safely and efficiently, please read the following before using it.

COMPONENTS 0.

(1) Shift up switch (7) Horn switch

(2) Shift down switch (8) Console lock lever

(3) FNR switch (9) Height adjustment lock lever

(4) Joystick steering lever (10) Angle, fore/aft adjustment lock lever

(5) Joystick ON/OFF switch (11) Console

(6) HI/LOW selector switch

SHIFT UP, SHIFT DOWN SWITCHES 0.

These switches (1) and (2) are used when shifting up or down,
regardless of whether the transmission is in the manual shift
mode or auto shift mode.
Press (1): Shift up
Press (2): Shift down

6-47
JOYSTICK STEERING SYSTEM ATTACHMENTS, OPTIONS

F-N-R SWITCH 0.
The F/N/R switch (3) at the top of the joystick steering lever is
used to switch the transmission between FORWARD and
REVERSE.

(F) position: FORWARD

(N) position: NEUTRAL
(R) position: REVERSE

Use the shift up and shift down switches at the top of the joy-
stick to change the speed range.

JOYSTICK STEERING LEVER 0.

Use this lever (4) to steer the machine to the left or right.
When traveling, operate this lever in the direction to turn the
machine.

(a): Left turn

(b): Right turn
(N): Neutral

JOYSTICK ON/OFF SWITCH 0.

When this switch (5) is turned ON, the joystick steering is
switched ON.
Position (a): ON (possible to steer with joystick)
Position (b): OFF (impossible to steer with joystick)

HI/LOW SELECTOR SWITCH 0.

This switch (6) is used to switch the steering speed between
HIGH and LOW.

Position (a): HI
The articulating speed of the machine is high in relationship to
the operation of the joystick, so this setting is suitable for com-
paratively fast cycle times.

Position (b): LOW

The articulating speed of the machine is low in relationship to
the operation of the joystick, so this setting is suitable for oper-
ations loading loose materials and materials that easily spill.

6-48
ATTACHMENTS, OPTIONS JOYSTICK STEERING SYSTEM

HORN SWITCH 0.
Press this switch (7) at the top of the joystick to sound the horn.
By using this switch, it is possible to sound the horn without
taking your hand off the joystick.

CONSOLE LOCK LEVER 0.

For details of this lever (8), see “GETTING IN OR OUT ( 6-51 )“.

HEIGHT ADJUSTMENT LOCK LEVER 0.

For details of this lever (9), see “ADJUSTMENT OF JOYSTICK CONSOLE ( 6-51 )“.

ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER 0.

For details of this lever (10), see “ADJUSTMENT OF JOYSTICK CONSOLE ( 6-51 )“.

STRUCTURE AND FUNCTION 0.

The joystick steering system is a system used to steer
wheel loaders with a lever instead of a steering wheel.
The joystick enables steering with small, light movements,
and helps to reduce operator fatigue.

When joystick ON/OFF switch (1) is turned ON, it becomes

possible to operate the steering with the joystick.

When the joystick steering is in use, the joystick pilot lamp on

the machine monitor lights up
.
On machines equipped with the joystick steering system, it
is possible to use joystick ON/OFF switch (1) to select the
steering and transmission operation method as shown in
the table below.
In addition, on machines equipped with joystick steering,
the transmission auto shift function is also included.
The differences between operation using the joystick and
operation using the steering wheel are as follows.

6-49
JOYSTICK STEERING SYSTEM ATTACHMENTS, OPTIONS

Selection Operation using joystick Operation using steering wheel

Joystick ON/OFF switch ON OFF

Steering using joystick (steering with

Steering Steering using steering wheel
steering wheel is also possible)

Operation using FNR switch Operation using transmission direc-

F/N/R
at top of joystick tional lever

Transmis-
Auto Auto
sion type

Shift mode
Transmis- selector Manual Auto (L, M, H) Manual Auto (L, M, H)
sion switch
Speed range
Automatic gear-
Selection of selection using Automatic gear-
Operation using shifting accord-
speed shift up, shift shifting according
gearshift lever ing to travel
range down switches at to travel speed
speed
top of joystick*

*: Does not shift up above speed range of gearshift lever.

OPERATION USING JOYSTICK LEVER AND OPERATION USING STEERING WHEEL

CAUTION
If the directional lever and joystick FNR switch are not at the neutral position, the neutral interlock cir-
cuit makes it impossible to switch the transmission directional control (when the joystick ON/OFF
switch is ON, it is switched from the direc-
tional lever to the joystick FNR switch; when the joystick ON/OFF switch is OFF, it is switched from
the joystick FNR switch to the directional lever).
Do not use the joystick when traveling on public roads.

Select joystick operation or steering wheel operation according to the work.

Steering using joystick
This is suited for continuous loading operations on jobsites with ample space where the loading operation can
be carried out with a comparatively relaxed cycle time.
Because operations can be carried out with a small movements and light operating effort, this is also suitable
for reducing operator fatigue when operating continuously.
Steering using steering wheel
This provides excellent fine control and ability to travel straight, so it is suitable for travel between jobsites and
for load and carry operations. In addition, it is also suitable for short cycle loading operations because the
upper part of the operator’s body is supported by the steering wheel when frequently switching between FOR-
WARD and REVERSE.

6-50
ATTACHMENTS, OPTIONS JOYSTICK STEERING SYSTEM

GETTING IN OR OUT 0.
WARNING
Always spring the joystick console up before getting in or out of the operator’s cab.
If the console is sprung up, the safety switch is turned OFF and the joystick is automatically stopped from
operating.

The joystick console is a spring-up type to make it easier for the operator to get in and out of the operator’s cab.
If the joystick is moved accidentally when the engine is running, the machine may articulate unexpectedly. To pre-
vent this danger, always spring the joystick console up when not using the joystick for operations and when getting
in or out of the operator’s cab.
1. Set lock lever (1) to the FREE position.
2. Spring console (2) up.
Turn it at least 90 degrees.
The safety switch is turned OFF and the joystick cannot be
operated.
3. When operating, lower joystick console (2) and push lock
lever (1) down to the LOCK position. The safety switch is Free
turned ON and the joystick can be operated.

Lock

ADJUSTMENT OF JOYSTICK CONSOLE 0.

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.

Adjusting height 0.
1. Operate lever (1) in the cancel direction and loosen the
lock.
2. Adjust the height of the console and set joystick (2) to the
desired position.
Amount of adjustment: 30 mm
Free
3. After setting, operate lever (1) to the LOCK position to lock
the console securely in position.
Lock

Free
Lock

Adjusting angle, fore/aft position 0.

1. Operate lever (3) in the cancel direction and loosen the lock.
2. Adjust the console and set joystick (2) to the desired position.
Amount of fore/aft adjustment: 45 mm
3. After setting, operate lever (3) to the LOCK position to lock the console securely in position.

6-51
JOYSTICK STEERING SYSTEM ATTACHMENTS, OPTIONS

OPERATION METHOD OF JOYSTICK STEERING SYSTEM 0.

WARNING
It is dangerous to turn the machine suddenly at high speed, or to turn on steep hills. Do not operate
the steering in such conditions.
When turning, the articulation stops at the position where the steering wheel is turned to, but if the
joystick is held in the tilted position, the body will articulate fully.
The feeling when operating the steering with the joystick is different from when operating with the
steering wheel, so be extremely careful until you have become used to operating the joystick.

Check the adjustment and operation before starting the engine. For details, see “CHECK BEFORE STARTING (
3-65 )“.
1. Before starting the engine, check the operation of the joy-
stick lever steering, check that the transmission directional
lever is at N, and that the surrounding area is safe.

REMARK
Under the following conditions, a warning may be given
when the engine is started.
If the FNR switch on the joystick is at F or R, the joy-
stick pilot lamp flashes, the central warning lamp lights
up, and the alarm buzzer sounds.
At the same time, “E00 J/S SW NEUTRAL“ is displayed
on the character display. In this condition, the engine
will not start, so set the FNR switch to N.
If the joystick is not at the N position, the joystick pilot
lamp flashes, the central warning lamp lights up, and
the alarm buzzer sounds.
At the same time, “E00 J/S LEVER POSI“ is displayed
on the character display. In this condition, the engine
will not start, so set the joystick to the N position.

2. Press the (a) part of the joystick ON/OFF switch to turn it

ON.

6-52
ATTACHMENTS, OPTIONS JOYSTICK STEERING SYSTEM

3. Operate the joystick in direction (b) to turn the machine to

the right; operate it in direction (a) to turn the machine to the
left.
The greater the angle of operation, the faster the articulating
speed becomes.

4. It is possible to switch the articulating speed with the HI/

LOW selector switch.
Select the speed to match the operation.
5. When the machine has articulated to the desired angle,
return the joystick to the N position.
The joystick will return automatically to the N position.
6. To return the direction of travel of the machine so that it trav-
els in a straight line, operate the joystick in the opposite
direction from the N position (for example, when the
machine is articulated to the right, operate the joystick to the
left).
7. Use the FNR switch at the top of the joystick lever to set the
transmission to the direction of travel.
N position: NEUTRAL
F position: FORWARD
R position: REVERSE

REMARK
If the position of the directional lever and the FNR switch
are different, the joystick pilot lamp flashes, the warning
lamp lights up, and the alarm buzzer sounds.
At the same time, “E00 SHIFT LEVER NEUTRAL“ is dis-
played on the character display. In this condition, the
machine will travel in the direction set by the directional
lever, so set the directional lever to N.

6-53
JOYSTICK STEERING SYSTEM ATTACHMENTS, OPTIONS

8. To change the speed range, use shift up switch (1) or shift

down switch (2) on the joystick.

REMARK
The joystick steering is unstable and dangerous to operate
at high speeds, so it is set so that the machine cannot
travel in 4th.
When joystick operation is selected, if the gearshift lever
is moved to 4th, or the joystick ON/OFF switch is turned
ON when the gearshift lever is at 4th, the central warning
lamp lights up and the alarm buzzer sounds.
At the same time, “E00 SHIFT LEVER“ is displayed on the
character display.
Set the gearshift lever within the range from 1st to 3rd.
In addition, when joystick operation is selected, for
machines equipped with a torque converter lock up
(option), the system is designed so that the machine does
not travel at high speed even if the torque converter lock
up switch is turned ON.

9. Press part (b) of the joystick ON/OFF switch to turn it OFF.

The joystick operation is then canceled.

6-54
ATTACHMENTS, OPTIONS EPC WORK EQUIPMENT LEVER

EPC WORK EQUIPMENT LEVER 0.

OPERATIONAL FEATURES 0.
EPC (Electronic Pilot Control) work equipment levers are offered as an option.
To improve the operating efficiency, the following three functions are provided.
Modulation function to prevent shock when stopping the bucket
Function to set the bucket stop position at two places - Top and Bottom (remote positioner)
It is possible to set the stop position from the operator’s seat.
Semiautomatic digging bucket - control function
Bucket tilt operation can be automatically done when digging.
Semiautomatic digging offers two selectable modes - Soft and Hard.

SWITCHES 0.

(1) Semi auto digging switch (3) Remote positioner lower mode switch

(2) Remote positioner raise mode switch (4) Remote positioner raise/lower set switch

6-55
EPC WORK EQUIPMENT LEVER ATTACHMENTS, OPTIONS

SAFETY LOCK LEVER (FOR WORK EQUIPMENT LEVER) 0.

WARNING
Before standing up from the operator’s seat, set the safety lock lever securely to the LOCK position.
If the safety lock lever is not at the LOCK position, and work equipment control lever (A) is touched by
mistake, it may lead to a serious accident.
If the safety lock lever is not placed securely at the LOCK position, the work equipment may move,
and this may lead to a serious accident or personal injury. Check that the lever is in the position
shown in the diagram.
When pulling up or pushing down the safety lock lever, be careful not to touch work equipment con-
trol lever (A).

This lever is a lock device for the work equipment control lever.
Push the safety lock lever down to lock it.

REMARK
This lever electrically locks the hydraulic circuit for the Free
work equipment, so if it is at the LOCK position, the work
equipment will not move even when work equipment con-
trol lever (A) is operated.
If the work equipment control lever is operated when this Lock
lever is at the LOCK position, the central warning lamp
lights up and the alarm buzzer sounds. At the same time,
“E00 WORK LEVER POSI“ is displayed on the character
display.

6-56
ATTACHMENTS, OPTIONS EPC WORK EQUIPMENT LEVER

SEMI AUTO DIGGING OPERATIONS 0.

SEMI AUTO DIGGING OPERATIONS 0.
Semi auto digging controls the bucket tilt operation automatically in order to make bucket operations easier for the
operator and reduce operator fatigue.
When doing the semi auto diggig operations, refer to the section of “DIGGING OPERATIONS ( 3-96 )“ in the chap-
ter, “WORKING POSSIBILITY ( 3-96 )“.

SEMI AUTO DIGGING SWITCH 0.

This switch turns the semi auto digging ON or OFF.
Position (a): HARD mode
The bucket tilt actuation is controlled intermittently.
Use this mode when handling heavy load materials.
Position (b): SOFT mode
The bucket tilt actuation is controlled continuously.
Use this mode when handling crushed rock or other light
load materials.
N position: Semi auto digging is switched OFF
In positions (a) and (b), the pilot lamp inside the switch lights
up.

METHOD OF OPERATION 0.
1. Turn the semi auto digging switch on the right switch panel
ON (select SOFT or HARD).
When the switch is turned ON, the pilot lamp inside the
switch lights up.
Position (a): HARD mode
Position (b): SOFT mode
N position: OFF

REMARK
For details of the selection of SOFT or HARD, see
“SELECTING DIGGING PATTERN ( 6-57 )“.

2. Lower the bucket to the ground as in the normal digging work and travel the machine forward. When the
bucket teeth dig into the ground, press the kick-down switch.
3. If the bucket tip is dug into the ground at boom RAISE, the bucket will automatically start tilting back.
Besides, when the boom hydraulically stalls in the digging work where the boom lever is pulled back and held in
the detent, the machine automatically starts the bucket to tilt back and maintains the optimum boom raise
speed thereafter.
The semi-auto digging pilot lamp on the main monitor lights up during automatic digging work.

SELECTING DIGGING PATTERN 0.

The following 2 modes can be selected for operating the bucket tilt.
The semi auto digging switch on the right switch panel is used to select the mode.
(1) SOFT mode
This mode is effective when handling crushed rock or other light load materials.
The bucket tilt actuation is controlled continuously.
(2) HARD mode
This mode is effective when handling heavy load materials.
The bucket tilt actuation is controlled intermittently.

MANUAL OPERATION DURING AUTOMATIC CONTROL 0.

It is possible to operate the bucket control lever to the TILT or DUMP position during automatic operation of the
bucket tilt.
As the bucket speed is proportional to the amount of lever operation, the bucket motion is the addition of the lever
operation and bucket speed programmed by the automatic control system.

6-57
EPC WORK EQUIPMENT LEVER ATTACHMENTS, OPTIONS

END OF CONTROL 0.
When the bucket reaches the end of the tilt, the control ends.

METHOD OF REMOTE POSITIONER 0.

It is possible to set the lift arm stop position by operating
remote positioner RAISE mode switch (1), remote positioner
LOWER mode switch (2), and remote positioner RAISE/
LOWER set switch (3) on the right switch panel.

REMARK
The RAISE mode is used when setting the lift arm position
at a point where the lift arm is above the horizontal posi-
tion; the LOWER mode is used when setting the stop posi-
tion at a point where the lift arm is below the horizontal
position.

REMOTE POSITIONER RAISE MODE SWITCH 0.

Use this switch (1) to turn on the remote positioner RAISE
mode (operating the lift arm at above the horizontal position).
Position (a): RAISE mode ON
Position (b): OFF

REMOTE POSITIONER LOWER MODE SWITCH 0.

Use this switch (2) to turn on the remote positioner LOWER
mode (operating the lift arm at below the horizontal position).
Position (a): LOWER mode ON
Position (b): OFF

6-58
ATTACHMENTS, OPTIONS EPC WORK EQUIPMENT LEVER

REMOTE POSITIONER RAISE/LOWER SET SWITCH 0.

Use this switch (3) to set the stopping position of the lift arm for
the remote positioner.
Position (a): After turning the remote positioner RAISE mode
switch ON, raise the lift arm to the desired position above
horizontal, then press the bottom (a) of this switch to set the
top lift arm stop position at that point.
Position (b): After turning the remote positioner LOWER mode
switch ON, lower the lift arm to the desired position below
horizontal, then press the bottom (b) of this switch to set the
bottom lift arm stop position at that point.
If the setting is carried out properly, the buzzer will give short
sounds.
If the setting cannot be carried out, the buzzer gives a long
sound.

METHOD OF OPERATION 0.
Setting with RAISE (or LOWER) mode

1. Press the top (a) of remote positioner RAISE (or LOWER)

mode switch (1) (or (2)) to turn the mode ON.
2. Raise (or lower) the bucket to the desired position.

3. In the case of the RAISE mode, press the top (a) (or the bot-
tom (b) for the LOWER mode) of remote positioner RAISE/
LOWER set switch (3).
The lift arm stop position is set.

If the setting is carried out properly, the buzzer will give

short sounds.
If the setting cannot be carried out, the buzzer gives a long
sound, so repeat the procedure from Step 1.

6-59
EPC WORK EQUIPMENT LEVER ATTACHMENTS, OPTIONS

6-60
INDEX
57
 INDEX

7-2
 INDEX

INDEX 0.
A J
6

ADJUSTING WORK EQUIPMENT .............................3-104 JOYSTICK STEERING SYSTEM .................................6-47

AIR CONDITIONER .....................................................3-60 ADJUSTMENT OF CONSOLE ..............................6-51
AUTO-GREASING SYSTEM ........................................6-37 COMPONENTS .....................................................6-47
OPERATION .........................................................6-37 GETTING IN OR OUT ...........................................6-51
AXLE SERIAL NO. PLATE .............................................1-9 OPERATION METHOD .........................................6-52
B STRUCTURE AND FUNCTION ............................6-49
BACKUP ALARM .........................................................3-56 L
C LIFTING MACHINE ....................................................3-113
CAB DOOR OPEN LOCK ............................................3-56 LIMIT VALUES FOR SLOPES .......................................5-6
CAB WINDOW OPEN LOCK .......................................3-56 LOCKING ...................................................................3-108
CAP WITH LOCK .........................................................3-53 LONG-TERM STORAGE ...........................................3-119
CE-CONFORMING EQUIPMENT ................................1-20 AFTER STORAGE ..............................................3-119
MANUFACTURER-SUPPLIED BEFORE STORAGE ...........................................3-119
CE-CONFORMING ................................1-21 DURING STORAGE ............................................3-119
CHECK AFTER STOPPING ENGINE ..........................3-83 LUBRICANTS .................................................................4-9
CHECK BEFORE STARTING ......................................3-65 FILLING CAPACITIES ..........................................4-10
CHECKS AFTER STARTING .......................................3-81 LUBRICATION CHART ...........................................4-9
CHECKS AFTER WORK ............................................3-109 M
COLD WEATHER OPERATION ................................3-116 MACHINE MONITOR .....................................................3-6
AFTER COLD WEATHER ...................................3-117 MAINTENANCE
AFTER COMPLETION OF WORK ......................3-117 LUBRICANTS AND OPERATING MEANS .............4-9
LOW TEMPERATURE ........................................3-116 MAINTENANCE SCHEDULE CHART .........................4-15
CONTROL LEVERS, PEDALS .....................................3-47 MOVING MACHINE OFF (FORWARD, REVERSE),
COOLANT ......................................................................4-9 STOPPING ...................................................................3-84
FILLING CAPACITIES ..........................................4-10 MULTIFUNCTION LEVER
D DIRECTIONAL SELECTOR SWITCH ...................6-42
DIRECTIONS OF MACHINE ..........................................1-7 DIRECTIONAL SELECTOR SWITCH
DMENSIONS ................................................................1-19 ACTUATION SWITCH ..........................................6-42
DUST INDICATOR .......................................................3-64 EXPLANATION OF COMPONENTS ....................6-40
E HANDLING ............................................................6-40
EMERGENCY LOWERING SYSTEM ..........................2-16 OPERATION .........................................................6-44
ENGINE SERIAL NO. PLATE AND POSITION .............1-8 WORK EQUIPMENT LEVER ................................6-41
EPC WORK EQUIPMENT LEVER N
OPERATIONAL FEATURES .................................6-55 NECESSARY INFORMATION .......................................1-8
REMOTE POSITIONER ........................................6-58 NOISE EMISSION LEVELS ...........................................5-4
SEMI AUTO DIGGING OPERATIONS .................6-57 O
SWITCHES ...........................................................6-55 OIL, FUEL, COOLANT ...................................................4-5
EQUIPMENT, CE-CONFORMING ...............................1-20 OPERATING DATA ......................................................1-19
EU DIRECTIVES ............................................................1-4 OPERATION ................................................................3-65
F OPERATION OF WORK EQUIPMENT ........................3-95
FOREWORD ..................................................................1-3 OUTLINE OF ELECTRIC SYSTEM ...............................4-7
FUEL ..............................................................................4-9 OUTLINES OF SERVICE ...............................................4-5
FILLING CAPACITIES ..........................................4-10 P
FUSE ............................................................................3-57 PARKING MACHINE ..................................................3-106
G PRECAUTIONS ..........................................................3-102
GENERAL PRECAUTIONS ...........................................2-4 PRECAUTIONS FOR MAINTENANCE ........................2-23
GENERAL VIEW ............................................................3-2 PRECAUTIONS FOR OPERATION .............................2-12
CONTROLS AND GAUGES ...................................3-3 BATTERY ..............................................................2-20
MACHINE ................................................................3-2 OPERATION .........................................................2-13
GREASE PUMP ...........................................................3-55 STARTING ENGINE .............................................2-12
GUIDE TO MAINTENANCE ...........................................4-3 TOWING ................................................................2-22
H TRANSPORTATION .............................................2-19
HANDLING CAB WIPER ..............................................3-64 PRECAUTIONS WITH TIRES ......................................2-30
HANDLING EPC WORK EQUIPMENT LEVER ...........6-55 R
HANDLING LOAD METER .............................................6-2 ROPS/FOPS-CAB SERIAL NO. PLATE ........................1-9
HANDLING LOAD METER DISPLAY .....................6-7 S
LOAD METER FUNCTIONS ...................................6-4 SAFETY BAR ...............................................................3-55
HANDLING THE TIRES .............................................3-109 SAFETY CRITICAL PARTS .........................................4-13
I SAFETY INFORMATION ...............................................1-5
INTRODUCTION ............................................................1-7 SAFETY LABELS ...........................................................2-2
LOCATION OF SAFETY LABELS ..........................2-2

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INDEX

SAFETY LABELS ....................................................2-3

SEAT OPERATOR SERIAL NO. PLATE .......................1-9
SERIAL NO. AND DISTRIBUTOR ...............................1-10
SERIAL NO. PLATE AND POSITION ............................1-8
SERVICE METER
POSITION .............................................................1-10
SERVICE PROCEDURE ..............................................4-17
CHECK BEFORE STARTING ...............................4-37
EVERY 100 HOURS SERVICE ............................4-38
EVERY 1000 HOURS SERVICE ..........................4-46
EVERY 2000 HOURS SERVICE ..........................4-48
EVERY 250 HOURS SERVICE ............................4-40
EVERY 4000 HOURS SERVICE ..........................4-55
EVERY 50 HOURS SERVICE ..............................4-38
EVERY 500 HOURS SERVICE ............................4-44
EVERY 8000 HOURS SERVICE ..........................4-57
INITIAL 1000 HOURS SERVICE ..........................4-17
INITIAL 250 HOURS SERVICE ............................4-17
INITIAL 50 HOURS SERVICE ..............................4-17
WHEN REQUIRED ...............................................4-18
SLOW-BLOW FUSE .....................................................3-59
STARTING ENGINE .....................................................3-77
STEERING TILT LOCK LEVER ...................................3-52
STOPPING ENGINE ....................................................3-83
SWITCHES ...................................................................3-34
T
TAKING OFF POWER .................................................3-59
TECHNICAL DATA .........................................................5-2
LIMIT VALUES FOR SLOPES ................................5-6
NOISE EMISSION LEVELS ....................................5-4
VIBRATION LEVELS ..............................................5-4
TIGHTENING TORQUES .............................................4-12
TORQUE LIST ..............................................................4-12
TOWING PIN ................................................................3-55
TRANSMISSION SERIAL NO. PLATE ...........................1-9
TRANSPORTATION ..................................................3-111
TRANSPORTATION PROCEDURE ..........................3-111
TROUBLESHOOTING ...............................................3-120
IF BATTERY IS DISCHARGED ..........................3-125
OTHER TROUBLE ..............................................3-128
TOWING THE MACHINE ....................................3-121
WHEN MACHINE RUNS OUT OF FUEL ............3-120
TURNING .....................................................................3-93
V
VIBRATION LEVELS ......................................................5-4
W
WARMING-UP OF STEERING HYDRAULIC ............3-118
WEAR PARTS ................................................................4-8
WEAR PARTS LIST .......................................................4-8
WEIGHTS .....................................................................1-19
WORKING POSSIBILITY .............................................3-96

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NOTES
78
NOTES NOTES

NOTES 0.

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NOTES NOTES

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