Operation & Maintenance

VENAM30501

Manual

WA320-8
WHEEL LOADER
SERIAL NUMBERS H70051 AND UP
H85001 AND UP

DANGER
Incorrect operation and maintenance of this machine ORIGINAL INSTRUCTIONS
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.

© 2017 KOMATSU
All Rights Reserved
Printed in Europe 11-2017
.
 FOREWORD

Komatsu recommends that any service parts used for maintenance, repair or
replacement of emission control systems be genuine new Komatsu or Ko-
matsu approved rebuilt parts or assemblies or others parts of equivalent
quality, and that the engine be serviced by an authorized Komatsu distribu-
tor. Failure to follow these recommendations could result in ineffective serv-
ice, damage to the product or safety risks (including personal injury or
death).

1-1
READ THIS MANUAL FOREWORD

READ THIS MANUAL

This manual gives details of the operation and methods of inspection and maintenance for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow funda-
mental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should
you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform im-
proper operation and maintenance of the machine. It may cause serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the in-
dicated location so that all relevant personnel can read it at any
time.
Keep it in the box for the Operation and Maintenance Manual
(1) on the left side of the operator's seat.

If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine
model name and the serial No. immediately to arrange for its replacement.
For details regarding the machine model name and the serial No., see the machine serial No. plate. In order to
arrange the proper Operation and Maintenance Manual, you will need to provide the machine model name and
the serial No.
This manual uses the International System of Units (SI) for units of measurement. For reference, units that have
been used in the past are given in { }.
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. If there is any question or suggestion, consult your Ko-
matsu distributor.
The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (1))
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, 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 your Komatsu distributor before
operating the machine.

EU DIRECTIVES
Machines supplied by us fulfil the Directive for Machinery 2006/42/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 stand-
ards and regulations in a specific country.
Notes on subsequent installation of electrical and electronic equipment and components.

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FOREWORD READ THIS MANUAL

Electrical and electronic equipment and/or components which have been installed subsequently, emit electro-
magnetic 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 dis-
turbance to the vehicle’s electronic system or other components. Above all, you must ensure that any subse-
quently installed electrical and electronic components comply with the EMV Directive 2014/30/EU 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 anten-
na.
• The transmitter unit must be spatially separated from the vehicle’s electronic system.
• Make sure when installing the antenna that this is installed correctly with good earth connection between
antenna and vehicle mass.
Also observe Komatsu and manufacturer’s installation instructions for wiring, installation and maximum permit-
ted power consumption.

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SAFETY INFORMATION FOREWORD

SAFETY INFORMATION
To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by-
standers, the precautions and warnings included in this manual and the safety signs attached to the machine
must always be observed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety mes-
sage.
This signal word indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury. It may also be used to alert against unsafe practices that may
cause property damage.

The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
If precautions described are not observed, the machine may be damaged or the service life
may be reduced.
This word is used for information that is useful to know.

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FOREWORD SAFETY LABELS

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.
This machine uses "Safety labels using pictograms" to indicate safety procedures.
SAFETY LABELS USING PICTOGRAMS
Safety pictograms use a picture to express a level of hazardous
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 availa-
ble 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 ques-
tions regarding information in this manual.
The numbers in the illustrations correspond to the numbers in ( ) in the text.

1-5
NOISE EMISSION LEVELS FOREWORD

NOISE EMISSION LEVELS

Two signs are attached to the machine that state the noise level produced.
• Sound pressure level at the operator’s station, measured
according to ISO 6396 (Dynamic test method, simulated
working cycle).
The maximum value of the standard deviation of the meas-
ured time-averaged A weighted emission sound pressure
level at the operator's position is 2.5 dB, in accordance
with ISO 11201.

• Sound power level emitted by the machine, measured ac-

cording to ISO 6395 (Dynamic test method, simulated
working cycle).
This is the guaranteed value as specified in European di-
rective 2000/14/EC.
This value includes an uncertainty of 2.5 dB.

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FOREWORD VIBRATION LEVEL

VIBRATION LEVEL
When used for its intended purpose, levels of vibration for the earth working machine transmitted from the oper-
ator’s seat are lower or equal to the test vibrations for the relative machinery class in compliance with ISO 7096.
The actual acceleration value of the upper limbs is less than 2.5 m/s2. The uncertainty for this value is 0.56 m/s2
according EN 12096:1997.
The actual acceleration value for the body is less than 0.5 m/s2. The uncertainty for this value is 0.20 m/s2 ac-
cording EN 12096:1997.
These values were determined using a representative machine and measured during the typical operating con-
dition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1
and ISO 5349.
Operating condition: V-shape loading
Guide to reduce vibration levels on machine
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
3. Keep the terrain where the machine is working and traveling 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
conditions
4. Use a seat that meets ISO 7096 and keep the seat maintained 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 adjustment 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 rough terrain
• Make the curve radius of traveling path as large as possible
• Travel at low speed then 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 worksites
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

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INTRODUCTION FOREWORD

INTRODUCTION
MAIN USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
• Digging work
• Leveling work
• Dozing work
• Loading work
For details of the work procedure, see “RECOMMENDED APPLICATIONS”.

DIRECTIONS OF MACHINE

(A) Front (D) Right

(B) Rear (E) Bucket
(C) Left (F) Operator's seat
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.

VISIBILITY FROM OPERATOR'S SEAT

This machine complies with the visibility standard (ISO5006).
This machine maintains a proximity visibility of a height of 1.5 m at a point 1 m away from the outside surface of
the machine, and a visibility for a radius of 12 m.
Protective structures
This machine is equipped with a structure to protect the operator (ROPS) conforming to ISO3471.

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FOREWORD ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION

ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS

EMISSION

About Engine Technology

This engine technology combines a Komatsu Diesel Particulate Filter (KDPF) and Komatsu’s Urea Selective
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union.
• Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the
exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process
to burn the soot is performed automatically to keep the filtering performance of KDPF high.
• Komatsu’s Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the
exhaust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust
gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and
decomposes the nitrogen oxides into nitrogen and water.
About Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid is the reagent for the SCR system.
DEF is the abbreviation for Diesel Exhaust Fluid, and is represented as DEF throughout this manual.
DEF is a colorless transparent and aqueous urea solution made with 32.5 % urea (AUS32) and 67.5 % deion-
ized water. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical
products, and fertilizer, etc.
Commercial DEF, commonly referred to as AdBlue® in the European Union, that quality standards are main-
tained in accordance with DIN70070 and ISO 22241-1, to be used.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).

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PRODUCT INFORMATION FOREWORD

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

LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-

AL NO. PLATE
This is located at the center of the front frame on the right side of the machine.
The design of the nameplate differs according to the district.

LOCATION OF ENGINE NUMBER PLATE

This is located at the right top of the engine rear part on the right side of the machine.

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FOREWORD PRODUCT INFORMATION

ROPS/FOPS SERIAL PLATE LOCATION

AXLE SERIAL PLATE LOCATION

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

PRODUCED BY
KOMATSU GERMANY GmbH, HANNOVER
FEDERAL REPUBLIC OF GERMANY FOR
Komatsu Ltd.,Tokyo,Japan

MODEL
PART NO.
SERIAL NO.

g0047137

TRANSMISSION SERIAL PLATE LOCATION

This plate is located in travel direction front, above the trans-
mission output. PRODUCED BY
KOMATSU GERMANY GmbH, HANNOVER
FEDERAL REPUBLIC OF GERMANY FOR
Komatsu Ltd.,Tokyo,Japan

MODEL
PART NO.
SERIAL NO.

g0047138

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PRODUCT INFORMATION FOREWORD

SEAT PLATE LOCATION

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

FLUORINATED GREENHOUSE GASES

Product contains fluorinated greenhouse gases.
Product contains
fluorinated
greenhouse gases

1.0 kg
HFC-134a
CO2 eq. 1.43 t
GWP 1430
09971-10101
g0027100

SERVICE METER LOCATION

It is at the center bottom of the machine monitor.

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Machine serial No.
Engine serial No.
Product identification
number (PIN)
Manufacturer name Komatsu Germany GmbH
Address Hanomag Strasse 9
30449 Hannover
Germany

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FOREWORD PRODUCT INFORMATION

Distributor name
Address
Phone/Fax
Service personnel

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DECLARATION OF CONFORMITY FOREWORD

DECLARATION OF CONFORMITY
The manufacturer:
Komatsu Germany GmbH
Hanomag Straße 9
30449 Hannover
Germany
Declares that this machine:
WA320-8*
Fulfils all the relevant provisions of following EC Directives:
Machine Directive 2006/42/EC
Electro Magnetic Compatibility Directive 2004/108/EC until 19 April 2016
2014/30/EU after 20 April 2016
Outdoor Noise Directive 2000/14/EC amended by 2005/88/EC
Radio Equipment and Telecommunications Terminal and 1999/5/EC until 12 June 2016
Equipment Directive
Radio Equipment Directive 2014/53/EU after 13 June 2016

*: explanation of machine category

Machine category Stand for:
WA Wheel loader

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FOREWORD RETROFITTING BY THIRD-PARTY SUPPLIERS

RETROFITTING BY THIRD-PARTY SUPPLIERS

In the case of wheel loaders with equipment and tools, which have not been part of a complete delivery ex
works, the responsibility for compliance with applicable laws and directives, in particular the European Machi-
nery Directive, lies with the customer who commissions retrofitting of the machine.
In the event of tools (e.g. loading shovels) being retrofitted by a third-party supplier, the technical specifications
of the manufacturer must be taken into account. For this purpose, or for further information, please be sure to
consult Komatsu or your local Komatsu dealer.

1-15
EXPLANATION OF ACRONYMS FOREWORD

EXPLANATION OF ACRONYMS
Acronyms Stand for:
KDPF Komatsu Diesel Particulate Filter
KVGT Komatsu Variable Geometry Turbo
KCCV Komatsu Closed Crankcase Ventilation
SCR Selective Catalytic Reduction
DEF Diesel Exhaust Fluid
ECSS Electrically Controlled Suspension System

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FOREWORD TABLE OF CONTENTS

TABLE OF CONTENTS
FOREWORD.................................................................................................................................................... 1-1
READ THIS MANUAL ............................................................................................................................... 1-2
EU DIRECTIVES ............................................................................................................................... 1-2
SAFETY INFORMATION .......................................................................................................................... 1-4
SAFETY LABELS ..................................................................................................................................... 1-5
NOISE EMISSION LEVELS ...................................................................................................................... 1-6
VIBRATION LEVEL................................................................................................................................... 1-7
INTRODUCTION ...................................................................................................................................... 1-8
MAIN USE OF MACHINE .................................................................................................................. 1-8
DIRECTIONS OF MACHINE.............................................................................................................. 1-8
VISIBILITY FROM OPERATOR'S SEAT ............................................................................................ 1-8
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION ..................................................... 1-9
PRODUCT INFORMATION..................................................................................................................... 1-10
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ...... 1-10
LOCATION OF ENGINE NUMBER PLATE ...................................................................................... 1-10
ROPS/FOPS SERIAL PLATE LOCATION.........................................................................................1-11
AXLE SERIAL PLATE LOCATION ....................................................................................................1-11
TRANSMISSION SERIAL PLATE LOCATION ..................................................................................1-11
SEAT PLATE LOCATION ................................................................................................................. 1-12
FLUORINATED GREENHOUSE GASES......................................................................................... 1-12
SERVICE METER LOCATION ......................................................................................................... 1-12
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR............................................................ 1-12
DECLARATION OF CONFORMITY ........................................................................................................ 1-14
RETROFITTING BY THIRD-PARTY SUPPLIERS................................................................................... 1-15
EXPLANATION OF ACRONYMS............................................................................................................ 1-16
SAFETY........................................................................................................................................................... 2-1
SAFETY.................................................................................................................................................... 2-2
SAFETY LABELS ..................................................................................................................................... 2-4
LOCATION OF SAFETY LABELS...................................................................................................... 2-5
CONTENTS OF SAFETY LABELS .................................................................................................... 2-7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE .................................... 2-15
PRECAUTIONS BEFORE STARTING OPERATION........................................................................ 2-15
PREPARATIONS FOR SAFE OPERATION ..................................................................................... 2-15
PRECAUTIONS TO PREVENT FIRE............................................................................................... 2-17
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................................. 2-18
DO NOT GET CAUGHT................................................................................................................... 2-20
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................................ 2-20
UNAUTHORIZED MODIFICATION .................................................................................................. 2-21
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS .................................................... 2-21
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ..................................................... 2-21
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-22
PRECAUTIONS FOR JOBSITE ....................................................................................................... 2-22
START ENGINE............................................................................................................................... 2-24
PRECAUTIONS FOR OPERATION ................................................................................................. 2-26
PRECAUTIONS FOR TRANSPORTATION...................................................................................... 2-31
TOWING AND BEING TOWED........................................................................................................ 2-32
PRECAUTIONS FOR MAINTENANCE ................................................................................................... 2-33
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................................... 2-33
PRECAUTIONS FOR CHECK AND MAINTENANCE ...................................................................... 2-37
TIRES .............................................................................................................................................. 2-41
PRECAUTIONS FOR DEF...................................................................................................................... 2-43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING .................................................. 2-43
PRECAUTIONS FOR ADDING ........................................................................................................ 2-43
PRECAUTIONS FOR STORING...................................................................................................... 2-43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE .................................................................... 2-43
OTHER PRECAUTIONS.................................................................................................................. 2-43

1-17
TABLE OF CONTENTS FOREWORD

OPERATION .................................................................................................................................................... 3-1

GENERAL VIEW....................................................................................................................................... 3-2
MACHINE EQUIPMENT NAME ......................................................................................................... 3-2
CONTROLS AND GAUGES NAMES ................................................................................................. 3-3
OTHER EQUIPMENT NAME ............................................................................................................. 3-7
EXPLANATION OF COMPONENTS ....................................................................................................... 3-10
EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................. 3-10
SWITCHES ...................................................................................................................................... 3-92
CONTROL LEVERS AND PEDALS ............................................................................................... 3-107
OTHER COMPONENTS .................................................................................................................3-110
MACHINE OPERATIONS AND CONTROLS ........................................................................................ 3-151
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...................................................... 3-151
METHOD FOR STARTING ENGINE.............................................................................................. 3-176
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................. 3-180
METHOD FOR STOPPING ENGINE ............................................................................................. 3-183
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE, AND SHIFTING GEAR)
AND STOPPING MACHINE ....................................................................................................... 3-184
METHOD FOR STEERING MACHINE........................................................................................... 3-192
METHOD FOR OPERATING WORK EQUIPMENT ....................................................................... 3-194
PRECAUTIONS FOR OPERATION ............................................................................................... 3-195
RECOMMENDED APPLICATIONS................................................................................................ 3-196
METHOD FOR ADJUSTING WORK EQUIPMENT POSTURE ...................................................... 3-201
REMOTE POSITIONER................................................................................................................. 3-201
METHOD FOR PARKING MACHINE ............................................................................................. 3-206
METHOD FOR CHECKING AFTER FINISHING WORK ................................................................ 3-208
LOCK ............................................................................................................................................. 3-208
HANDLE TIRE ................................................................................................................................3-211
HANDLE AIR CONDITIONER............................................................................................................... 3-213
EXPLANATION OF AIR CONDITIONER EQUIPMENT.................................................................. 3-214
METHOD FOR OPERATING AIR CONDITIONER......................................................................... 3-219
TRANSPORTATION.............................................................................................................................. 3-223
TRANSPORTATION PROCEDURE ............................................................................................... 3-223
LOADING AND UNLOADING WITH TRAILER .............................................................................. 3-223
METHOD FOR LIFTING MACHINE ............................................................................................... 3-227
COLD WEATHER OPERATION............................................................................................................ 3-229
COLD WEATHER OPERATION INFORMATION ........................................................................... 3-229
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER................................ 3-230
PRECAUTIONS IN COLD WEATHER ........................................................................................... 3-230
AFTER COLD WEATHER SEASON .............................................................................................. 3-230
PRECAUTIONS FOR LONG-TERM STORAGE ................................................................................... 3-231
PREPARATION FOR LONG-TERM STORAGE ............................................................................. 3-231
MAINTENANCE DURING LONG-TERM STORAGE...................................................................... 3-231
STARTING MACHINE AFTER LONG-TERM STORAGE ............................................................... 3-231
TROUBLES AND ACTIONS ................................................................................................................. 3-233
ACTIONS WHEN RUNNING OUT OF FUEL ................................................................................. 3-233
PRECAUTIONS FOR TOWING MACHINE .................................................................................... 3-234
PRECAUTIONS FOR DISCHARGED BATTERY ........................................................................... 3-237
OTHER TROUBLE......................................................................................................................... 3-240
MAINTENANCE............................................................................................................................................... 4-1
PRECAUTIONS FOR MAINTENANCE ..................................................................................................... 4-2
CHECK SERVICE METER READING ............................................................................................... 4-2
KOMATSU GENUINE REPLACEMENT PARTS ................................................................................ 4-2
KOMATSU GENUINE LUBRICANTS ................................................................................................. 4-2
ALWAYS USE CLEAN WASHER FLUID ............................................................................................ 4-2
FRESH AND CLEAN LUBRICANTS .................................................................................................. 4-2
CHECK DRAINED OIL AND USED FILTER....................................................................................... 4-2
PRECAUTIONS FOR REFILLING OIL OR FUEL .............................................................................. 4-2
PRECAUTIONS FOR ADDING DEF ................................................................................................. 4-2

1-18
FOREWORD TABLE OF CONTENTS

WELDING INSTRUCTIONS............................................................................................................... 4-2

DO NOT DROP THINGS INSIDE MACHINE ..................................................................................... 4-2
PRECAUTIONS FOR KDPF .............................................................................................................. 4-2
PRECAUTIONS FOR SCR ASSEMBLY ............................................................................................ 4-3
DUSTY JOBSITES............................................................................................................................. 4-3
AVOID MIXING OIL............................................................................................................................ 4-3
LOCK INSPECTION COVERS .......................................................................................................... 4-3
BLEED AIR FROM HYDRAULIC CIRCUIT ........................................................................................ 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ............................................................. 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE...................................................................... 4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE........................................... 4-4
CLOSE ENGINE SIDE COVER SECURELY...................................................................................... 4-4
OUTLINE OF MAINTENANCE.................................................................................................................. 4-5
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5
HANDLE ELECTRICAL COMPONENTS ........................................................................................... 4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS .............................................................. 4-10
MAINTENANCE SCHEDULE.................................................................................................................. 4-12
MAINTENANCE SCHEDULE TABLE............................................................................................... 4-12
MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED ................... 4-13
MAINTENANCE PROCEDURE .............................................................................................................. 4-15
INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) .................................. 4-15
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ............................ 4-15
WHEN REQUIRED .......................................................................................................................... 4-15
CHECKS BEFORE STARTING........................................................................................................ 4-44
EVERY 50 HOURS MAINTENANCE ............................................................................................... 4-46
EVERY 100 HOURS MAINTENANCE ............................................................................................. 4-46
EVERY 250 HOURS MAINTENANCE ............................................................................................. 4-47
EVERY 500 HOURS MAINTENANCE ............................................................................................. 4-53
EVERY 1000 HOURS MAINTENANCE ........................................................................................... 4-57
EVERY 2000 HOURS MAINTENANCE ........................................................................................... 4-63
EVERY 4000 HOURS MAINTENANCE ........................................................................................... 4-80
EVERY 4500 HOURS MAINTENANCE ........................................................................................... 4-83
EVERY 8000 HOURS MAINTENANCE ........................................................................................... 4-83
EVERY 9000 HOURS MAINTENANCE ........................................................................................... 4-84
SPECIFICATIONS ........................................................................................................................................... 5-1
SPECIFICATIONS .................................................................................................................................... 5-2
SPECIFICATIONS: WA320-8............................................................................................................. 5-2
ATTACHMENTS AND OPTIONS ..................................................................................................................... 6-1
BUCKET AND TIRE SELECTION............................................................................................................. 6-2
HANDLE JOYSTICK STEERING SYSTEM .............................................................................................. 6-3
EXPLANATION OF COMPONENTS IN JOYSTICK STEERING SYSTEM......................................... 6-3
FUNCTION AND STRUCTURE OF JOYSTICK STEERING SYSTEM............................................... 6-8
PRECAUTIONS FOR HANDLING JOYSTICK STEERING SYSTEM................................................. 6-8
METHOD FOR HANDLING JOYSTICK STEERING SYSTEM........................................................... 6-9
SELECTION OF OPERATION WITH JOYSTICK STEERING LEVER AND STEERING WHEEL .....6-11
METHOD FOR GETTING ON OR OFF TO OPERATOR'S CAB .......................................................6-11
METHOD FOR ADJUSTING JOYSTICK CONSOLE ....................................................................... 6-12
HANDLE HYDRAULIC TYPE QUICK COUPLER ................................................................................... 6-14
EXPLANATION OF COMPONENTS ON MACHINES WITH QUICK COUPLER .............................. 6-14
METHOD FOR REMOVING ATTACHMENT .................................................................................... 6-15
METHOD FOR REMOVING ATTACHMENT .................................................................................... 6-17
METHOD FOR INSTALLING ATTACHMENT ................................................................................... 6-18
METHOD FOR INSTALLING ATTACHMENT ................................................................................... 6-20
PRECAUTIONS FOR USING HYDRAULIC TYPE QUICK COUPLER............................................. 6-23
HANDLE FORK ...................................................................................................................................... 6-24
EXPLANATION OF COMPONENTS ON MACHINES WITH FORK ................................................. 6-24
MACHINE OPERATIONS AND CONTROLS ................................................................................... 6-25
PCS (PROPORTIONAL CONTROL SWITCH)........................................................................................ 6-31

1-19
TABLE OF CONTENTS FOREWORD

LCD UNIT ........................................................................................................................................ 6-31

METHOD FOR SETTING PCS ........................................................................................................ 6-33
REPLACEMENT PARTS.................................................................................................................................. 7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS.......................................................................... 7-2
DEFINED LIFE PARTS LIST.............................................................................................................. 7-2
CONSUMABLE PARTS ............................................................................................................................ 7-3
CONSUMABLE PARTS LIST ............................................................................................................. 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .......................................................................... 7-4
LUBRICATION CHART ...................................................................................................................... 7-4
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE ............................................................................................................................................. 7-6
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS .............. 7-8
INDEX.............................................................................................................................................................. 8-1

1-20
 SAFETY

Please read and make sure that you fully understand the precautions descri-
bed in this manual and the safety labels on the machine. When operating or
servicing the machine, always follow these precautions strictly.

2-1
SAFETY SAFETY

SAFETY
SAFETY LABELS ............................................................................................................................................ 2-4
LOCATION OF SAFETY LABELS............................................................................................................. 2-5
CONTENTS OF SAFETY LABELS ........................................................................................................... 2-7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........................................... 2-15
PRECAUTIONS BEFORE STARTING OPERATION............................................................................... 2-15
ENSURE SAFE OPERATION .......................................................................................................... 2-15
UNDERSTAND THE MACHINE ....................................................................................................... 2-15
PREPARATIONS FOR SAFE OPERATION ............................................................................................ 2-15
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT ................................................................. 2-15
INSPECT MACHINE ........................................................................................................................ 2-15
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT ............................................. 2-15
KEEP MACHINE CLEAN ................................................................................................................. 2-15
PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT ...................................................... 2-16
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ................................................................... 2-16
IF ANY PROBLEM IS FOUND ......................................................................................................... 2-16
PRECAUTIONS TO PREVENT FIRE...................................................................................................... 2-17
ACTIONS IF FIRE OCCURS ........................................................................................................... 2-17
PREVENT FIRE............................................................................................................................... 2-17
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE.................................................................... 2-18
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE ..................................... 2-18
NO JUMPING ON OR OFF MACHINE............................................................................................. 2-19
NO PEOPLE ON ATTACHMENTS ................................................................................................... 2-19
LIFTING OF PERSONNEL PROHIBITED........................................................................................ 2-19
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT.............................................. 2-19
PRECAUTIONS WHEN LEAVING MACHINE .................................................................................. 2-19
EMERGENCY EXIT FROM OPERATOR'S CAB .............................................................................. 2-20
PRECAUTIONS FOR CLEANING CAB GLASS............................................................................... 2-20
DO NOT GET CAUGHT.......................................................................................................................... 2-20
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............................................................... 2-20
UNAUTHORIZED MODIFICATION ......................................................................................................... 2-21
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ........................................................... 2-21
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ............................................................ 2-21
PRECAUTIONS FOR OPERATION ............................................................................................................... 2-22
PRECAUTIONS FOR JOBSITE .............................................................................................................. 2-22
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS................................................................. 2-22
PRECAUTIONS WHEN WORKING ON LOOSE GROUND ............................................................. 2-22
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES........................................................................ 2-22
ENSURE GOOD VISIBILITY............................................................................................................ 2-23
CHECK SIGNS AND SIGNALMAN'S SIGNALS............................................................................... 2-23
BEWARE OF ASBESTOS DUST ..................................................................................................... 2-24
START ENGINE...................................................................................................................................... 2-24
USE WARNING TAGS ..................................................................................................................... 2-24
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ........................................................ 2-24
PRECAUTIONS WHEN STARTING ENGINE .................................................................................. 2-25
IN COLD WEATHER........................................................................................................................ 2-25
START ENGINE WITH JUMPER CABLES ...................................................................................... 2-25
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-26
CHECKS BEFORE OPERATION..................................................................................................... 2-26
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE ............................................... 2-26
PRECAUTIONS WHEN TRAVELING............................................................................................... 2-27
PRECAUTIONS WHEN TRAVELING ON SLOPES ......................................................................... 2-28
METHOD OF USING BRAKES ........................................................................................................ 2-28
PRECAUTIONS WHEN OPERATING MACHINE............................................................................. 2-29
PROHIBITED OPERATIONS ........................................................................................................... 2-29
PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES.................................. 2-30
PRECAUTIONS WHEN PARKING MACHINE ................................................................................. 2-30

2-2
SAFETY SAFETY

PRECAUTIONS FOR TRANSPORTATION............................................................................................. 2-31

PRECAUTIONS WHEN LOADING AND UNLOADING .................................................................... 2-31
TOWING AND BEING TOWED............................................................................................................... 2-32
PRECAUTIONS FOR TOWING AND BEING TOWED..................................................................... 2-32
PRECAUTIONS FOR MAINTENANCE .......................................................................................................... 2-33
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE .......................................... 2-33
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ....................................... 2-33
KEEP WORK PLACE CLEAN AND TIDY ........................................................................................ 2-33
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE .......................................... 2-33
ONLY AUTHORIZED PERSONNEL................................................................................................. 2-33
APPOINT LEADER WHEN WORKING WITH OTHERS .................................................................. 2-33
STABILITY ....................................................................................................................................... 2-33
GUARDS ......................................................................................................................................... 2-34
END OF SERVICE LIFE .................................................................................................................. 2-34
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ........................... 2-34
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING .......................................... 2-35
TURN OFF ECSS SWITCH BEFORE PERFORMING INSPECTION AND MAINTENANCE ........... 2-36
PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS...................... 2-36
PRECAUTIONS FOR WORKING AT HIGH PLACES ...................................................................... 2-36
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT .......................... 2-36
USE PROPER TOOLS .................................................................................................................... 2-37
PRECAUTIONS FOR CHECK AND MAINTENANCE ............................................................................. 2-37
TURN BATTERY DISCONNECT SWITCH TO OFF POSITION ....................................................... 2-37
PRECAUTIONS FOR WELDING ..................................................................................................... 2-37
HANDLE BATTERY ......................................................................................................................... 2-37
PRECAUTIONS WHEN USING HAMMER ...................................................................................... 2-38
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT ............................................................... 2-38
PRECAUTIONS FOR HIGH-TEMPERATURE OIL........................................................................... 2-39
PRECAUTIONS FOR HIGH-TEMPERATURE PARTS..................................................................... 2-39
PRECAUTIONS FOR HIGH-PRESSURE OIL.................................................................................. 2-39
PRECAUTIONS FOR HIGH-PRESSURE FUEL .............................................................................. 2-39
HANDLE HIGH-PRESSURE HOSES AND PIPING ......................................................................... 2-39
PRECAUTIONS FOR NOISE........................................................................................................... 2-40
HANDLE ACCUMULATOR AND GAS SPRING ............................................................................... 2-40
PRECAUTIONS FOR COMPRESSED AIR...................................................................................... 2-40
MAINTENANCE OF AIR CONDITIONER ........................................................................................ 2-40
CHEMICAL HAZARD....................................................................................................................... 2-40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS .......................................................... 2-40
METHOD FOR SELECTING WINDOW WASHER FLUID................................................................ 2-41
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS................................................................. 2-41
TIRES ..................................................................................................................................................... 2-41
HANDLE TIRES............................................................................................................................... 2-41
PRECAUTIONS FOR STORING TIRES .......................................................................................... 2-42
PRECAUTIONS FOR DEF............................................................................................................................. 2-43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING ......................................................... 2-43
PRECAUTIONS FOR ADDING ............................................................................................................... 2-43
PRECAUTIONS FOR STORING............................................................................................................. 2-43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE ........................................................................... 2-43
OTHER PRECAUTIONS......................................................................................................................... 2-43

2-3
SAFETY LABELS SAFETY

SAFETY LABELS
k WARNING
Be sure that you fully understand the correct position, content and how to avoid a danger shown in the
safety labels.

Handle the warning signs and safety labels used on this machine as follows.
• Always keep the safety labels clean so that you can read it properly. When cleaning the safety labels, do
not use organic solvents or gasoline. These may cause the labels to peel off.
• If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details
of the part numbers for the safety labels, see this manual or the actual label, and place an order to your
Komatsu distributor.
• There are also other labels in addition to the warning signs and safety labels. Handle those labels in the
same way.

2-4
SAFETY SAFETY LABELS

LOCATION OF SAFETY LABELS

2-5
SAFETY LABELS SAFETY

(1) Caution before operating (15) Caution for modification of ROPS/FOPS

(2) Caution when leaving operator's seat (16) Prohibition of start by short-circuiting
(3) Caution when traveling in reverse (17) Caution for cleaning cooler core
(4) Caution for electric cables (18) Emergency escape
(5) Prohibition of trespassing (19) Caution when closing emergency escape right
(6) Caution for frame lock bar window
(7) Caution for high-temperature coolant (20) Caution for high-temperature turbocharger
(8) Caution for high temperature oil and hydraulic oil (21) Caution for hot exhaust pipe
(9) Caution for handling battery cable (22) Caution for high-pressure common rail
(10) Caution for explosion (23) Caution for blast site
(11) Prohibition of getting on or off fender (Machines equipped with KOMTRAX)
(Machines equipped with rear full-length fender) (24) Caution for handling battery
(12) Caution while engine is running (25) Caution when traveling in reverse
(13) Caution for nearing machine (Machine with rearview camera)
(14) Prohibition of entering beneath work equipment (26) Caution for handling DEF

2-6
SAFETY SAFETY LABELS

CONTENTS OF SAFETY LABELS

Caution before operating
“09651-A0481”
• Warning!
• Read manual before operation, maintenance, disassembly,
assembly and transportation.

Caution when leaving the operator's seat

“09654-C0481”
• Sign indicates a hazard of unexpected moving of stopped
machine.
• Lower working device to ground, move safety lever to lock
position and take engine key with you before leaving ma-
chine.

Caution when traveling in reverse

“09802–D0880”
• Sign indicates a hazard of rear working and advancing be-
hind.
• Read the operation and maintenance manual before oper-
ation.

2-7
SAFETY LABELS SAFETY

k WARNING
To prevent SEVERE INJURY or DEATH, do the following before moving machine or its attachments:
• Honk horn to alert people nearby.
• Be sure no one is on or near the machine.
• Use spotter if view is obstructed.
Follow above even if the machine is equipped with back-up alarm and mirrors.

Caution for electric cables

“09801-C0481”
• Sign indicates an electrocution hazard if machine is
brought too near electric power lines.
• Keep a safe distance from electric power lines.

Prohibition of trespassing
“09162-C0641”
• Sign indicates a crush hazard between the articulating
parts of the vehicle.
• Keep away from the vehicle when it is moving.

2-8
SAFETY SAFETY LABELS

Caution for frame lock bar

“09161-C0641”
• Sign indicates a crush hazard between the articulating
parts of the vehicle.
• Lock vehicle with lock bar to avoid movement during main-
tenance and transportation.

Caution for high-temperature coolant

“09653-A0641”
• Sign indicates a burn hazard from spurting hot water or oil
if radiator or hydraulic tank is uncapped while hot.
• Allow radiator or hydraulic tank to cool before removing
cap.

Caution for high temperature oil and hydraulic oil

“09653-A0641”
• Sign indicates a burn hazard from spurting hot water or oil
if radiator or hydraulic tank is uncapped while hot.
• Allow radiator or hydraulic tank to cool before removing
cap.

2-9
SAFETY LABELS SAFETY

Caution for handling battery cable

“09808-A1201”
• Sign indicates an electric hazard from handling the cable.
• Read the operation and maintenance manual for safe and
proper handling.

Caution for explosion

“09659-A057B”
• Sign indicates an explosion hazard.
• Never drill, cut with gas, hit or disassemble. Also keep
open flame away.

Prohibition of getting on or off fender

(Machines equipped with rear full-length fender)
“09805-C0641”
• Sign indicates a hazard of falling.
• Do not stand on this place here.

Caution while engine is running

“09667-A0880”
• Sign indicates a hazard of rotating parts, such as belt.
• Turn off before inspection and maintenance.

2-10
SAFETY SAFETY LABELS

Caution for nearing machine

“09806–C1201”
• Sign indicates a hazard of being run over by moving vehi-
cle.
• Keep a safe distance from vehicle when it is moving.

Prohibition of entering beneath work equipment

“09807-C1201”
• Sign indicates a crush hazard from falling off of working de-
vice.
• Keep away when the working device is raised.

Caution for modification of ROPS

“09620-A2001”
“09620-A3001”
• If any modification is applied to the ROPS or FOPS, it may
affect the strength and may not be comply with the stand-
ard. Do not drill, cut, or weld on the ROPS or FOPS struc-
ture. Any modification is prohibited.
• ROPS or FOPS may provide less protection if it has been
structurally damages or involved roll-over. Consult Komat-
su Distributor in that case.
• Always wear seat belt when moving.

2-11
SAFETY LABELS SAFETY

Prohibition of start by short-circuiting

“09842-A0481”
• Start the engine only after sitting down in the operator’s
seat.
• Do not attempt to start the engine by short-circuiting the
engine starting circuit. Such an act may cause a serious
bodily injury or fire.

Caution for cleaning cooler core

“09667-A0481”
• Sign indicates a hazard of rotating parts, such as belt.
• Turn off before inspection and maintenance.

Emergency escape
“425-93-51110”

2-12
SAFETY SAFETY LABELS

Caution when closing emergency escape right window

“421-93-4990”

Caution for high-temperature turbocharger

“09817-A0753”
• Sign indicates a burn hazard from touching heated parts,
such as engine, motor, or muffler during or right after oper-
ation.
• Never touch when hot.

Caution for hot exhaust pipe

“09817-A0753”
• Sign indicates a burn hazard from touching heated parts,
such as engine, motor, or muffler during or right after oper-
ation.
• Never touch when hot.

Caution for high-pressure common rail

“6271-81-2981”
• Do not open high pressure fuel system with engine run-
ning. Engine operation causes high fuel pressure.
• High pressure fuel spray can cause serious injury or death.

Caution for blast site

(Machines equipped with KOMTRAX)
“09845-00480”
• Sign indicates an explosion hazard caused by active radio
transmitter at a blast zone.
• Keep machine at a safe distance from a blast zone and
detonator.

2-13
SAFETY LABELS SAFETY

Caution for handling battery

“09664-62A11”, or “09664-62D11”
• Sign indicates a hazard of battery.
• Read the operation and maintenance manual for safe and
proper handling.
Caution when traveling in reverse
(Machine with rearview camera)
“09833-C0881”
• When backing up, rear of machine is displayed on monitor.
Before moving, look back and at mirror and monitor to con-
firm that no one is rear of machine.
• Failure to do so can result in serious injury or death.

Caution for handling DEF

“09632-61480”
• DEF only. TO avoid engine damage or fire, fill with DEF
only.
• Never use diesel fuel.

ᵎᵗᵔᵑᵐᵋᵔᵏᵒᵖᵎ

2-14
 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE-
SAFETY NANCE

GENERAL PRECAUTIONS COMMON TO OPERATION

AND MAINTENANCE
Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per-
forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine
carefully and obey the warnings.

PRECAUTIONS BEFORE STARTING OPERATION

ENSURE SAFE OPERATION
• Only trained and authorized personnel can operate and maintain the machine.
• Follow all safety, precautions, and instructions in this manual when operating or performing inspection or
maintenance on the machine.
• If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely
operate or repair your machine may be severely impaired, putting yourself and everyone else on your job
site in danger.
• When working with another operator or with the person on the worksite traffic duty, discuss the content of
the operation beforehand and use the determined signals when performing the operation.

UNDERSTAND THE MACHINE

Before operating the machine, read this manual thoroughly. If there is any place in this manual that you do not
understand, ask the person in charge of safety for explanation.

PREPARATIONS FOR SAFE OPERATION

PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT
• Be sure that all guards, covers, cameras, and mirrors are in their proper position. Repair them immediately
if they are damaged.
• Understand the using method of the safety related devices and use them properly.
• Never remove any safety related devices. Always keep them in good operating condition.

INSPECT MACHINE
Check the machine before starting operations. If any abnormality is found, do not operate the machine until re-
pairs of the problem location have been completed.

WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

• Do not wear loose clothes or any accessories. If any of
these catch the control levers or protruding parts, it may
cause the machine to move unexpectedly, it is extremely
dangerous.
• Always wear a hard hat and safety shoes. Wear protective
eyeglasses, mask, gloves, ear plugs, and safety belt when
operating or maintaining the machine.
• Long hair hanging out from the hard hat is dangerous that
it may get caught up in the machine. Tie the hair up and be
careful not to be caught.
• Check that all personal protective items function properly
before using them.

KEEP MACHINE CLEAN

• If you get on or off the machine or perform inspection and maintenance on the machine with mud or oil, you
may slip and fall, and it is dangerous. Wipe off any mud or oil from the machine. Always keep the machine
clean.

2-15
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE-
NANCE SAFETY

• If water gets into the electrical system, electric devices will

cause malfunctions, and the machine will cause error. If
the machine cause error, it may move unexpectedly and
cause serious personal injury or death. When washing the
machine with water or steam, do not allow the water or
steam to come into direct contact with electrical compo-
nents.
• If high-pressure water is sprayed directly onto camera, it
may cause failure. Defective camera cannot monitor sur-
rounding area. When cleaning, do not allow the high-pres-
sure water to get into camera directly, and wipe off any dirt
with soft cloth.
• When cleaning camera, if you stand on an unstable place, or take an unstable posture, you may fall and be
injured. Put proper stepladder or step on the level and firm ground, and clean the camera in secure posture.

PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT

• 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 seri-
ous accident.
• Do not leave tools or machine parts lying around inside the operator's compartment. If tools or parts get into
the control devices, it may obstruct operation and cause the machine to move unexpectedly, resulting in
serious personal injury or death.
• Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
• Do not use a cellular phone when driving or operating the machine. This may lead to mistakes in operation,
and may cause serious personal injury or death.
• Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.

PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

Observe the following precautions to prepare for action if any
serious personal injury or death or fire should occur.
• Be sure that fire extinguishers have been provided and
read the labels to ensure that you know how to use them
for the possibility of fires.
• The fire extinguisher can be fastened to the inside cabin
wall, see picture.
1: Fastening points
• Perform periodic inspection and maintenance to ensure ,&
that the fire extinguisher can always be used.
• Provide a first aid kit in the storage point. Perform periodic
checks and add to the contents if necessary.

IF ANY PROBLEM IS FOUND

If you find any problem 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 per-
son in charge and take the necessary action. Do not operate the machine until the problem has been corrected.

2-16
 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE-
SAFETY NANCE

PRECAUTIONS TO PREVENT FIRE

ACTIONS IF FIRE OCCURS
• Turn the starting switch to OFF position, and stop the engine.
• Use the handrails and steps to escape from the machine.
• Do not jump off the machine. There is the danger of falling and it may cause personal injury.
• The fume generated by a fire contains harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
• After a fire, harmful compounds may be left. If it touches your skin, it may have a bad influence on your
body.
Be sure to wear rubber gloves when handle the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.

PREVENT FIRE
Fire caused by fuel, oil, coolant, or window washer fluid
Do not bring any open flame close to flammable substances
such as fuel, oil, coolant, or window washer fluid. There is a
danger that they may catch fire. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
,&
• Be careful not to spill fuel on overheated surfaces or on
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other combustible materials into a
safe container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel fuel or gasoline. There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain combustible liquids. ,&
• Determine well-ventilated areas for storing oil and fuel.
Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation of combustible material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other combustible materials accumulated
or affixed around the engine exhaust manifold, muffler, or battery, or inside the undercovers.
• To prevent fires from spreading sparks or burning particles from other fires, remove any combustible materi-
als such as dry leaves, chips, pieces of paper, coal dust, or any other combustible materials accumulated
around the cooling system (radiator, oil cooler) or inside the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.

2-17
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE-
NANCE SAFETY

• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused from piping
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. There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury.
Fire around the machine due to highly heated exhaust gas
This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF).
KDPF is a device to purify the soot in the exhaust gas. Exhaust gas temperature may increase during the purifi-
cation process (regeneration). Do not bring any combustible material close to the outlet of the exhaust pipe.
When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to the regener-
ation disable to prevent fire hazards due to highly heated exhaust gas during the aftertreatment devices regen-
eration. For setting, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-126)”.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica-
tions.
• When taking the electrical power for the lighting equipment from the machine, see “POWER SUPPLY OUT-
LET (3-115)”.

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE

USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE
To prevent personal injury caused by slipping or falling off the machine, always observe the following.
• Use the handrails and steps marked by arrows in the fig-
ure When getting on and off the machine.

• Always face the machine and maintain at least three-point

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

,&

• Before getting on and off the machine, check the handrails and steps if there is any oil, grease, or mud on
them. Wipe it off immediately not to slip if any. In addition, tighten any loose bolt of the handrails and steps.
If the handrails and steps are damaged or deformed, they need to be repaired immediately. Ask your Ko-
matsu distributor to perform this work.
• 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.
• Do not try to get on a tire from the step in the rear side of the machine or the step beside the cab.

2-18
 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE-
SAFETY NANCE

• Do not get on or off the machine with tools in your hand.

NO JUMPING ON OR OFF MACHINE

Getting on or off the moving machine can cause serious personal injury or death. Always observe the following.
• 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
Never let anyone ride on the work equipment or other attachments. There is a hazard of falling and suffering
serious personal injury or death.

LIFTING OF PERSONNEL PROHIBITED

Under no circumstances should this machine be used for the lifting of personnel.

PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT

When standing up from the operator's seat to adjust the opera-
tor's seat, be sure to lower the work equipment completely to
the ground, lock the work equipment by pressing work equip-
ment lock switch (1) (pilot lamp lights up) and stop the engine
by setting parking brake switch (2) to ON (operation) position
(A).
If the control levers are touched by mistake, there is danger
that the machine may suddenly move and cause serious per-
sonal injury or death.

PRECAUTIONS WHEN LEAVING MACHINE

If the proper procedures are not taken when parking the machine, the machine may suddenly move off by itself,
and this may lead to serious personal injury or death. Always observe the following.

2-19
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE-
NANCE SAFETY

Whenever leaving the machine, be sure to lower the work

equipment to the ground, lock the work equipment by pressing
work equipment lock switch (1) (pilot lamp lights up) and stop
the engine by setting parking brake switch (2) to ON (opera-
tion) position (A). In addition, lock all places and always take
the key with you and keep it in the specified location.

EMERGENCY EXIT FROM OPERATOR'S CAB

Machines equipped with a cab have a door on the left side and a door for an alternate exit on the right side. If
the door on the left side does not open, use the right side alternate exit door.

PRECAUTIONS FOR CLEANING CAB GLASS

Clean the cab glass to ensure visibility during operation.
Make sure to clean the glass with a mop from the ground.

DO NOT GET CAUGHT

• If the clearance at the articulating portion changes and you
get caught in it, you will suffer serious personal injury or
death. Do not allow anyone to come inside the articulation
range.
• The clearance in the area around the work equipment
changes according to the movement of the link. If you are
caught, this may lead to serious personal injury or death.
Do not allow anyone near any of the rotating or telescopic
parts.
,&

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

The operator's compartment is equipped with a structure (such as ROPS, FOPS) to protect the operator by ab-
sorbing the impact energy.

2-20
 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE-
SAFETY NANCE

As for the machine equipped with ROPS, if the machine weight

(mass) exceeds the certified value (shown on ROLL-OVER
PROTECTIVE STRUCTURE (ROPS) CERTIFICATION plate),
ROPS will not be able to fulfill its function. Do not increase ma-
chine weight beyond the certified value by modifying the ma-
chine or by installing attachments to the machine.
Also, if the function of the protective equipment is impeded, the
protective equipment will not be able to protect the operator,
and the operator may suffer injury. Always observe the follow-
ing. ,&

• If the machine is equipped with a protective structure, do

not remove the protective structure and perform operations without it.
• If the protective structure is welded, or holes are drilled in it, or it is modified in any other way, its strength
may drop. Any modification is prohibited.
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be
reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu
distributor.
• Even if the protective structure is installed, always fasten your seat belt properly when operating the ma-
chine. If you do not fasten your seatbelt properly, it cannot display its effect.
Always fasten your seat belt while operating the machine.

UNAUTHORIZED MODIFICATION
• Komatsu will not be responsible for any personal injuries, product failures, physical loss or damage, or influ-
ence on the environment resulting from modifications made without authorization from Komatsu.
• Any modification made without authorization from Komatsu can create hazards. Before making a modifica-
tion, consult your Komatsu distributor.

PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

• Any personal injuries, product failures, physical loss or damage, or influence on the environment resulting
from the use of unauthorized attachments or parts will not be the responsibility of Komatsu.
• When installing optional parts or attachments, contact your Komatsu distributor for advice to any potential
problems or safety and legal requirements.
• When installing and using optional attachments, always read the instruction manual for the attachment, and
the general information related to attachments in this manual.

PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING

The engine exhaust gas contains substances that may damage
your health or even cause death. Start or operate the engine in
a place where there is good ventilation. If the engine or ma-
chine must be operated inside a building or underground,
where the ventilation is poor, take steps to ensure that the en-
gine exhaust gas is removed and that ample fresh air is
brought in.

,&

2-21
PRECAUTIONS FOR OPERATION SAFETY

PRECAUTIONS FOR OPERATION

PRECAUTIONS FOR JOBSITE
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS
On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start-
ing operations, always check the following to confirm that there is no danger on the jobsite.
• Always be careful when performing operations near materials such as thatched roofs, dry leaves or dry
grass, because they are easily combustible and may cause fire.
• Check the terrain and condition of the ground at the jobsite, and determine the safest method of operation.
Do not operate in a dangerous area where landslides or rockfall may occur.
• If water lines, gas lines, or high-voltage electrical lines may
be buried under the jobsite, contact the management com-
pany to identify their locations, and be careful not to dam-
age any of these lines.
• Take necessary measures to prohibit other personnel from
coming close to the machine during operation.
• In particular, if you need to operate on a road, protect pe-
destrian and cars by designating a person for jobsite traffic
duty or by installing fences around the jobsite.
• When traveling or operating in shallow water or on soft
ground, check the water depth, speed of the current, con-
dition of bedrock, and shape of the ground beforehand. Always avoid any place that will obstruct travel.
• Maintain the travel path on the jobsite so that there is no obstruction to travel operations.

PRECAUTIONS WHEN WORKING ON LOOSE GROUND

• Avoid driving or operating the machine near the edge of cliffs, road edges, and deep ditches. The ground
may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil is weak in these areas, after
heavy rain or blasting or after earthquakes.
• When working on embankments or near excavated ditches, there is a hazard that the weight and vibration
of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the
ground is safe and to prevent the machine from rolling over or falling.

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause
serious personal injury or death. On jobsites where the machine may go close to electric cables, always observe
the following.
• 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.
• Even going close to high-voltage cables can cause electric
shock. Always maintain a safe distance (see the table) be-
tween the machine and the electric cable. Check with the
local power company about the voltage of cables and safe
operating procedure before starting operations.
Voltage of Cables Safety Distance
100 V, 200 V Min. 2 m
6600 V Min. 2 m
22000 V Min. 3 m
66000 V Min. 4 m

2-22
SAFETY PRECAUTIONS FOR OPERATION

Voltage of Cables Safety Distance

154000 V Min. 5 m
187000 V Min. 6 m
275000 V Min. 7 m
500000 V Min. 11 m
• To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera-
tor's seat, and be careful not to touch the chassis with any exposed part of your body.
• Use a signalman to give warning if the machine approaches too close to the electric cables.
• When performing operations near high voltage cables, prohibit anyone other than related persons to come
close to the machine during operation.
• 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 confirmed that the electricity has been shut
off. Also, prohibit any other persons to come close to the machine.

ENSURE GOOD VISIBILITY

Although this machine is equipped with mirrors and cameras to ensure good visibility, there are places that can-
not be seen from the operator's seat. Be careful when performing operation.
When traveling or performing operations in places with poor visibility, it is dangerous and may cause serious
personal injury or death because it is difficult to check for obstacles and condition of the jobsite. When traveling
or performing operations in places with poor visibility, always observe the following.
• Allocate a signalman for jobsite duty if there are areas where the visibility is poor.
• Only one signalman should give signals.
• When working in dark places, turn on the working lamp and headlamps installed to the machine, and set up
additional lighting equipment in the work area if necessary.
• Stop operations if the visibility is poor because of mist, snow, rain, or dust.
• When checking the mirrors installed to the machine, remove all dirt and adjust the angle of the mirror before
starting the work to ensure good visibility.
• Clean off any dirt from the lens of cameras installed to the machine, and make sure that the camera gives a
clear view.
• The rear view monitor is provided to secure the rear side visibility. If, however, an obstacle is detected on
the monitor, you must confirm it with your eyes.

CHECK SIGNS AND SIGNALMAN'S SIGNALS

If signals and labels are not clear, serious personal injury can result from downward slip, overturn or accidental
contact with nearby people or obstacles. Always observe the following.
• Set up labels to inform of road edges and soft ground. If the visibility is not good, position a conductor if
necessary. Operator should pay careful attention to the labels and follow the instructions from the conduc-
tor.
• Only one signalman should give signals.
• Make sure that all workers understand the meaning of all signals, signs, and labels before starting work.

2-23
PRECAUTIONS FOR OPERATION SAFETY

BEWARE OF ASBESTOS DUST

Asbestos dust in the air can cause lung cancer if it is inhaled.
There is danger of inhaling asbestos when working on jobsite
where demolition work is performed or industrial waste is han-
dled. Always observe the following.
• Spray water to keep down the dust.
• Do not use compressed air.
• If there is danger that there may be asbestos dust in the
air, always operate the machine from an upwind position,
and make sure that all workers operate on the upwind ,&
side.
• All workers should use anti-dust masks.
• Prohibit other personnel from coming close to the machine during operation.
• Always observe the regulations for jobsite and environmental standards.
This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing
asbestos. Always use Komatsu genuine parts.

START ENGINE
USE WARNING TAGS
If there is a “DANGER! Do NOT operate!” warning tag dis-
played, it means that someone is performing inspection and
maintenance of the machine. If the warning tag is ignored and
the machine is operated, the person performing inspection or
maintenance may be caught in the rotating parts or moving
parts. It is dangerous and may cause serious personal injury or
death. Do not start the engine or touch the levers.

CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE

Perform the following checks before starting the engine at the beginning of the day's work to ensure that there is
no problem with the operation of the machine. If these checks are not performed properly, problems may occur
with the operation of the machine, and there is a danger which may lead to serious personal injury or death.
• Remove all dirt from the surface of the window glass to ensure a good view.
• Perform the walk-around check.
• Remove all dirt from the surface of the lens of the headlamps, working lamps, and combination lamps, and
check that they light up correctly.

2-24
SAFETY PRECAUTIONS FOR OPERATION

• Check the coolant level, fuel level, DEF level, and oil level in engine oil pan, check for clogging of the air
cleaner, and check for damage to the electric wiring.
• Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake
pedal, and check that the pedals work properly.
• Adjust the operator's seat to a position for easier operation. Check that there is no damage or wear to the
seat belt or mounting clamps.
• Check that the gauges work properly, check the angle of the mirror, and check that the control levers are all
at NEUTRAL position.
• Adjust the mirrors to have a good rear view from the operator's seat.
• Check that there are no persons or obstacles above, below, or in the area around the machine.
• Check that the parking brake switch is at ON (operation) position.
• Check that frame lock bar (1) is fixed securely at FREE po-
sition (F).
• Adjust the angle of each camera so that the surrounding
area can be seen clearly from the operator's seat.
• If snowfalls adhered to a camera, eliminate them with se-
curing your safety by using a stepladder.

PRECAUTIONS WHEN STARTING ENGINE

The machine may suddenly move off and this may lead to serious personal injury or death. Always observe the
following.
• Start the engine only while sitting down in the operator's seat.
• When starting the engine, sound the horn as a warning.
• Prohibit other personnel to get on the machine.
• Do not attempt to start the engine by short-circuiting the engine starting circuit. This may cause fire, serious
personal injury or death.
• Check that the backup alarm (alarm buzzer when machine travels in reverse) works properly.

IN COLD WEATHER
• If the warm-up operation is not performed thoroughly, and the work equipment is operated, the reaction of
the work equipment to the operation of the control levers and pedals will be slow and the movement of it
may not be what the operator intended. Be sure to perform the warm-up operation. Particularly in a cold
weather, be sure the warming-up operation is completed.
• 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 and cause the battery to explode.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check
that there is no leakage of electrolyte before starting.

START ENGINE WITH JUMPER CABLES

If any mistake is made in the method of connecting the jumper cables, it may cause the battery to explode, so
always observe the following.

2-25
PRECAUTIONS FOR OPERATION SAFETY

• Always wear protective eyeglasses and rubber gloves

when starting the engine by using the jumper cables.
• When connecting a normal machine to a failed machine
with the jumper cables, always use the normal machine
with the same battery voltage as the failed machine.
• When starting the engine with the jumper cables, perform
the starting operation with 2 workers (one worker sitting in
the operator's seat and the other working with the battery).
• When starting from another machine, be careful that the
normal machine does not contact with the failed machine.
• When connecting the jumper cables, turn the starting
switch to OFF position for both the failed machine and the normal machine. If the failed machine has a bat-
tery disconnect switch, turn it to OFF position, and turn it ON again after connecting the cables.
For details of operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-119)”.
It is dangerous that the machine may move when the power is connected.
• Be sure to connect the positive (+) cable first when installing the jumper cables. Disconnect the negative (-)
cable (ground side) first when removing them.
• When disconnecting the jumper cables, take care not to bring the clips in contact with each other or with the
machine.
• For the starting procedure with the jumper cables, see OPERATION, “START ENGINE WITH JUMPER CA-
BLES (3-239)”.

PRECAUTIONS FOR OPERATION

CHECKS BEFORE OPERATION
If the checks before starting are not performed properly, the machine will be unable to display its full perform-
ance. It is dangerous and may cause serious personal injury or death.
When performing the checks, move the machine to a wide area with no obstructions, and pay careful attention
to the surroundings. Prohibit other personnel from coming close to the machine during operation.
• Fasten the seatbelt. When the brakes are applied sudden-
ly, the operator may be thrown out of the operator's seat. It
is dangerous and may cause personal injury.
• Check the operating condition of the machine, work equip-
ment, and travel and brake systems.
• Check for any problem in the sound, vibration, heat and
smell of the machine, or abnormalities of instruments. Also
check that there is no leakage of oil or fuel.
• If any problem is found, repair it immediately.

• Before starting to travel or operations, check that frame

lock bar (1) is fixed securely at FREE position.

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

• Always lock all the doors and windows of the operator's compartment in position regardless of whether it is
open or closed.

2-26
SAFETY PRECAUTIONS FOR OPERATION

• Prohibit other personnel to get on the machine.

• If there are any persons in the area around the machine,
there is danger that they may be hit or caught by the ma-
chine, and this may lead to serious personal injury or
death. Always observe the following before traveling.
• Always operate the machine only when seated on the
operator's seat.
• Before starting to move, check again that there is no
people or obstacle in the surrounding area.
• Before moving, sound the horn to warn people in the
surrounding area.
• Check that the backup alarm (alarm buzzer when machine travels in reverse) works properly.
• If there is an area in the rear of the machine which cannot be seen, allocate a conductor.
Always be sure to perform the above precautions even when the machine is equipped with mirrors and cam-
eras.
When traveling downhill through inertia, set the direction of the directional lever or directional selector switch to
the position that matches the machine traveling direction. If the directional lever or directional selector switch is
set to the direction opposite to that of the machine travel, engine stall can result and it is very dangerous.

PRECAUTIONS WHEN TRAVELING

Serious personal injury or death can result from tipping over of the traveling machine or its accidental contact.
Always observe the following.
• Never turn the key in the starting switch to OFF position when the machine is traveling. If the engine stops
when the machine is traveling, the steering wheel becomes heavy to operate, and this will cause a wrong
operation of the steering wheel and may lead to serious personal injury or death. If the engine stops, de-
press the brake pedal immediately to stop the machine.
• When driving the machine or performing operations, always keep a safe distance from people, structures,
or other machines to avoid coming into contact with them.
• When traveling on a level ground, keep the work equip-
ment approximately 30 cm above the ground. If that height
is not maintained between the work equipment and the
ground, the work equipment may get stuck in the ground
and the machine may tip over.
When you are forced to operate the multifunction mono-
lever, do it after stopping the travel once.
• Try to avoid traveling over obstacles. If the machine has to
travel over an obstacle, keep the work equipment close to
the ground and travel at low speed. The machine tips over
easily to the right or left. Do not drive it over obstacles
which make the machine tilt largely to the right or left.
• When driving the machine on the rough ground, drive it at low speed and do not operate the steering sud-
denly. There is a danger that the machine may tip over. The work equipment may hit the ground, and the
machine may lose its balance, or it may damage the machine or structures in the area.
• When using the machine, to prevent serious personal injury or death caused by the work equipment or by
the machine tipping over due to overloading, do not use the machine beyond the permitted performance of
the machine such as the maximum permitted load for the structure of the machine.
• When passing over bridges or structures, check first that the structure is strong enough to support the
weight of the machine.
• 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 machine body or work equipment hit anything.

2-27
PRECAUTIONS FOR OPERATION SAFETY

• If you drive the machine at high speed continuously for a long time, the tires will overheat and the internal
pressure will become abnormally high. This may cause the tires to burst. If a tire bursts, it produces a large
destructive force, and this may cause serious injury or death.

PRECAUTIONS WHEN TRAVELING ON SLOPES

To prevent the machine from tipping over or slipping to the side, always observe the following.
• Keep the work equipment at height (A) of approximately 20
to 30 cm above the ground. In case of emergency, lower
the work equipment to the ground immediately to help
stopping the machine.

• Always drive the machine straight up or down a slope.

Driving the machine at an angle or across the slope is ex-
tremely dangerous.
• Do not turn on slopes or drive across slopes. Always go
down to a flat place to change the position of the machine,
then drive it on to the slope again.

• Drive the machine at low speed on the grass or fallen leaves. Even with slight slopes, there is a hazard that
the machine may slip.
• If the engine should stop on a slope, depress the brake pedal immediately, lower the bucket and apply the
parking brake to stop the machine.
• When driving the machine downhill, drive it slowly at low speed. Depress the brake pedal or use the engine
brake as necessary.
• When the bucket is loaded, direct the bucket toward the hill top both in uphill and downhill travel. When
driving the machine with the bucket directing downhill, it is liable to tip over and is dangerous.

METHOD OF USING BRAKES

• Do not put your foot on the brake pedal unnecessarily. If the machine travels with your foot on the brake
pedal, the brake operates constantly and heats abnormally, and is disabled and that can cause an accident.
• Do not depress the brake pedal repeatedly more than necessity.
• When traveling downhill, always use the engine brake, and use the brake pedal as well.

2-28
SAFETY PRECAUTIONS FOR OPERATION

PRECAUTIONS WHEN OPERATING MACHINE

• When using the machine, to prevent serious personal injury or death caused by the work equipment or by
the machine tipping over due to overloading, do not use the machine beyond the permitted performance of
the machine such as the maximum permitted load for the structure of the machine.
• If the engine cannot be started again after it has stopped, turn the starting switch key to ON position, and
immediately operate the multifunction mono-lever to lower the work equipment to the ground. (The accumu-
lator is capable of working only for a limited time after the engine is stopped.)
• 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, do not start, turn, or stop
the machine suddenly. There is danger that the machine
may tip over.

• When handling unstable loads such as round and cylindri-

cal materials, and stacked plates, they may drop onto the
operator's compartment if the work equipment is raised
high, and cause serious personal injury or death.
• When handling unstable loads, be careful not to raise the
work equipment too high or tilt the bucket backward too
much.
• If the work equipment is suddenly lowered or stopped, the
reaction may cause the machine to tip over. Particularly
when carrying a load, be sure to operate the work equip-
ment carefully.
• When performing the operation in tunnels, under bridges,
under electric wires, or other places where the height is
limited, be extremely careful not to let the work equipment
etc. hit anything.
• To prevent accidents caused by hitting other objects, al-
ways operate the machine at a speed which is safe for op-
eration, particularly in confined spaces, indoors, and in pla-
ces where there are other machines.

PROHIBITED OPERATIONS
If the machine tips over or falls, or the ground at the working point collapses, it may lead to serious personal
injury or death. Always observe the following.

2-29
PRECAUTIONS FOR OPERATION SAFETY

• Do not dig the work face under an overhangs. There is a

danger that the work face will collapse.
• When digging, never thrust the bucket into a load at an an-
gle. This will bring an excessive load on the machine and
will reduce the machine life.
• Wall surface digging by using of driving force is dangerous.
An excessive load will be brought on the machine and this
will cause damage to the machine. Never try such prac-
tice.
• Never perform digging operations on a downhill slope. An
excessive load will be brought on the machine and this will
damage the machine.
• Do not use the bucket or boom for crane operations. There
is a danger that the machine may tip over and the load
may fall.
• Do not pass the bucket over the heads of other workers or
over the operator's seat of dump trucks or other hauling
equipment. There is a danger that the load may spill or the
bucket may hit the dump truck and cause serious personal
injury or death.

PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES

• Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the ma-
chine, and do not perform abrupt lever operation. Machine may slip even on a slight slope. Be particularly
careful when working on slopes.
• Frozen road becomes soft when the temperature rises, and the machine may tip over or be not able to es-
cape. Be particularly careful when working on frozen road.
• When traveling on snow-covered roads, always fit tire chains.
• It is dangerous that the machine enters deep snow. The machine may tip over or become buried in the
snow. Be careful not to go off the road or to get trapped in a drift of snow.
• When performing snow removal, the road and objects placed beside the road are buried in the snow and
cannot be seen. Be careful.
• When traveling on snow-covered slopes, never apply the foot brake suddenly. Reduce the speed and use
the engine brake while applying the foot brake intermittently (depress the brake intermittently several
times). If necessary, lower the work equipment to the ground to stop the machine.

PRECAUTIONS WHEN PARKING MACHINE

Unexpected move of the parked machine can cause serious personal injury or death. Always observe the fol-
lowing.
• Park the machine on a firm, level ground.
• Select a place where there is no hazard of landslides, fall-
ing rocks, or flooding.
• Lower the work equipment to the ground.

2-30
SAFETY PRECAUTIONS FOR OPERATION

• When leaving the machine, lock the work equipment by

pressing the work equipment lock switch (1) (pilot lamp
lights up) and set the parking brake switch (2) to ON (oper-
ation) position (A), then stop the engine.
• Always close the operator's cab door, and use the key to
lock all the equipment in order to prevent any unauthorized
person from operating the machine. Always remove the
key, take it with you, and keep it in the specified place.

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

blocks under the tires to prevent the machine from moving.

PRECAUTIONS FOR TRANSPORTATION

When the machine is transported on a trailer, serious personal injury or death may result because of the acci-
dent during transportation. Always observe the following.
• Always check the machine dimensions carefully. Depending on the work equipment installed, the machine
weight, transportation height, and overall length differ.
• Check beforehand that all bridges and other structures on the transportation route are strong enough to
withstand the combined weight of the transporter and the machine being transported.
• This machine needs to be divided into components for transportation depending on the regulation. When
transporting the machine, consult your Komatsu distributor.
• Lock the frame with the frame lock bar to prevent the machine from articulating.
• Fit chains to the front frame and the rear frame to hold the machine securely in position.

PRECAUTIONS WHEN LOADING AND UNLOADING

If handling is improper when loading or unloading the machine, it is dangerous that the machine may tip over or
fall. It requires particular attention. Always observe the following.
• Perform loading and unloading on a firm, level ground only. Avoid road edge or place near the cliff.

2-31
PRECAUTIONS FOR OPERATION SAFETY

• Always use ramps of adequate strength. Be sure that the

ramps are wide, long, and thick enough to provide a safe
loading slope. Take suitable steps to prevent the ramps
from moving out of position or coming off.
(1) Chocks
(2) Ramp
(3) Width of ramps: Same width as tires
(4) Angle of ramp: Max. 15 °
(5) Block
• Be sure the ramp surface and the platform of trailer are
clean and free of grease, oil, ice, water and other loose materials. If any, remove them. Remove dirt around
the undercarriage of the machine. On a rainy day, in particular, be extremely careful since the ramp surface
is slippery.
• Run the engine at low idle and drive the machine slowly at low speed.
• Never correct your steering on the ramps. If necessary, drive off the ramps onto the ground, correct the di-
rection, then enter the ramps again.
• When loading or unloading to an embankment or platform, make sure that it has suitable width, strength,
and grade.
• For machines equipped with a cab, always lock the door after loading the machine. To prevent the door
from opening during transportation.
• When it is necessary to remove handrails and steps, take care not to lose removed handrails and steps.
Install the removed handrails and steps securely.

TOWING AND BEING TOWED

PRECAUTIONS FOR TOWING AND BEING TOWED
Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or
drawbar or the method of towing a disabled machine and being towed may lead to serious personal injury or
death.
For towing, see “PRECAUTIONS FOR TOWING MACHINE (3-234)”.
• Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the ma-
chine being towed.
• Never use the wire rope which has cut strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
• Always wear leather gloves when handling the wire rope.
• Never tow a machine on a slope.
• During the towing operation, never stand between the tow-
ing machine and the machine being towed.

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SAFETY PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE
During inspection and maintenance, always display the “DAN-
GER! Do NOT operate!” warning tag.
If there is a “DANGER! Do NOT operate!” warning tag dis-
played, it means that someone is performing inspection and
maintenance of the machine. If the warning tag is ignored and
the machine is operated, the person performing inspection or
maintenance may be caught in the rotating parts or moving
parts. It is dangerous and may cause serious personal injury or
death. Do not start the engine or touch the levers.
If necessary, put up signs around the machine as well.
Warning tag part No. 09963-A1640
When not using this warning tag, keep it in the toolbox. If there
is no toolbox, keep it in the pocket for Operation and Mainte-
nance Manual.

KEEP WORK PLACE CLEAN AND TIDY

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances
that will cause you to slip. Always keep the work place clean the tidy to enable you to perform 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 your-
self.

SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE

• Stop the machine on a firm, level ground.
• Select a place where there is no hazard of landslides, falling rocks, or flooding.

ONLY AUTHORIZED PERSONNEL

As long as maintenance of the machine is continued, do not allow unauthorized person to come near the work-
place. They might get unexpected personal injury from, for instance, touching machine. Do not allow anyone
except the workers concerned to enter the workplace. If necessary, employ a guard.

APPOINT LEADER WHEN WORKING WITH OTHERS

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow
his/hers instructions during the operation in order to prevent personal injuries caused by being caught or
pinched.

STABILITY
• When dismantling or assembling the machine for the purpose of maintenance, repair or transportation, al-
ways ensure that at each stage of the process, care is taken to ensure that the machine remains stable.
Failure to do this could result in serious injury or death.

2-33
PRECAUTIONS FOR MAINTENANCE SAFETY

GUARDS
• Guards are installed in the area of the engine to protect personnel from moving parts. These guards should
only be removed by Komatsu service engineer unless specific instructions are given in this manual.

END OF SERVICE LIFE

• For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor.

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or
high-pressure liquids, it is dangerous and may cause serious personal injury or death. Always observe the fol-
lowing.
• Lower the work equipment to the ground and stop the en-
gine before performing any inspection and maintenance.

• Stop the engine (work equipment is lowered to the

ground), and turn the starting switch to ON position. Press
the work equipment lock switch (2) to release the work
equipment lock (the pilot lamp goes off), then operate the
multifunction mono-lever (1) to RAISE and LOWER posi-
tion fully 2 to 3 times to release the remaining pressure in
the hydraulic circuit. Then lock the work equipment (the pi-
lot lamp lights up) by pressing the work equipment lock
switch (2).
After releasing the remaining pressure in the hydraulic cir-
cuit, turn the starting switch to OFF position.
• Set parking brake switch (3) to ON (operation) position (A)
to apply the parking brake, then put blocks in front of and
behind the tires to prevent the machine from moving.

2-34
SAFETY PRECAUTIONS FOR MAINTENANCE

• Set frame lock bar (4) to LOCK position (L) to lock the front
and rear frame.

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent accident, do not perform maintenance with the engine running. When it is necessary to perform the
maintenance with the engine running, always observe the following.
• 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.
• Rotating parts such as the fan, fan belt are dangerous that
they may easily catch a body part or an object someone
wears. Be careful not to come close to the rotating part.
• Never drop or insert tools or other objects into the fan, fan
belt, or other rotating parts. They may contact the rotating
parts and break, and be scattered. It is dangerous.
• If the automatic active regeneration of KDPF starts during
maintenance work, surroundings of KDPF become high
temperature. ,&
When performing maintenance work, perform the after-
treatment devices regeneration disable according to “HAN-
DLE Komatsu Diesel Particulate Filter (KDPF) (3-126)”.
• Lower the work equipment to the ground and press work
equipment lock switch (1) to lock the work equipment (pilot
lamp lights up) and prevent it from moving.

• Set parking brake switch (2) to ON (operation) position (A)

to apply the parking brake, then put blocks in front of and
behind the tires to prevent the machine from moving.
• Do not touch the control levers or steering system. If it is
necessary to operate the control lever or steering system,
always give a signal to your fellow workers and have them
take refuge to a safe place.

2-35
PRECAUTIONS FOR MAINTENANCE SAFETY

TURN OFF ECSS SWITCH BEFORE PERFORMING INSPECTION AND MAINTE-

NANCE
Before starting the inspection and maintenance, lower the bucket to the ground and turn the ECSS switch to
OFF position, then stop the engine. Never turn the ECSS switch to ON position during the inspection or
maintenance.

PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS

• Appoint a leader before starting removal or installation operations for attachments.
• Place attachments that have been removed from the ma-
chine in a stable condition so that they do not fall. And take
steps to prevent unauthorized persons from entering the
storage area.

,&

PRECAUTIONS FOR WORKING AT HIGH PLACES

When working at high places, use a step ladder or other stand to ensure that the work can be performed safely.
There is a danger falling from high place that can lead to serious personal injury or death.

PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT

Machine or work equipment may fall, and it is dangerous that serious personal injury or death may occur. Al-
ways observe the following.
• Do not perform inspection and maintenance under the work equipment which is not lowered to the ground.
Always lower the work equipment to the ground when performing inspection and maintenance.
• Make sure the hoists or hydraulic jacks you use are in
good repair and strong enough to handle the weight of the
component. Never use hydraulic jacks at places where the
machine is damaged, bent, or twisted. Never use if the
strand of wire rope is frayed, twisted or pinched. Never use
bent or distorted hooks.
• If it is necessary to raise the work equipment or a compo-
nent and then go under it to carry out inspection or mainte-
nance, support the work equipment or component securely
with blocks and stands (1) strong enough to support their ,&
weight. If the work equipment or component is not support-
ed, they may come down, causing serious personal injury or death.
• Never use concrete blocks for supports. Concrete blocks
may break under even light loads.

2-36
SAFETY PRECAUTIONS FOR MAINTENANCE

USE PROPER TOOLS

Use the tools suited to the task and use them correctly. Using
damaged, deformed, or low quality tools, or making improper
use of the tools may cause serious personal injury or death.

,&

PRECAUTIONS FOR CHECK AND MAINTENANCE

TURN BATTERY DISCONNECT SWITCH TO OFF POSITION
In the following cases, turn the starting switch to OFF position and check that the system operating lamp is off.
Then set the battery disconnect switch to OFF position and remove the switch key.
If you check and handle battery without turning battery disconnect switch to OFF position, serious personal in-
jury or death by such as an electric shock may occur.
• When storing the machine for a long time (more than 1 month)
• When repairing the electrical system
• When performing electric welding
• When handling the battery
• When replacing the fuse, etc.

PRECAUTIONS FOR WELDING

Welding operations must always be performed by a qualified welder and in a place equipped with proper equip-
ment. There is a hazard of gas, fire, or electric shock when performing welding, so never allow any unqualified
person to perform welding.

HANDLE BATTERY
Before inspecting or handling the battery, turn the key in the starting switch to OFF position and check that the
system operating lamp is off. Then set the battery disconnect switch to OFF position and remove the switch key.
Danger of battery exploding
When the battery is being charged, flammable hydrogen gas is generated and may explode. In addition, the bat-
tery electrolyte includes dilute sulphuric acid. Any mistake in handling may cause serious personal injury, explo-
sion, or fire, so always observe the following.
• Do not use or charge the battery if the battery electrolyte is below LOWER LEVEL mark. This may cause
an explosion. Always perform periodic inspection of the battery electrolyte level, and add purified water
(such as a commercial battery fluid) to UPPER LEVEL mark.
• Do not use a dry wipe to clean the battery. A wet wipe will prevent fire or explosion from static electricity.
• Do not smoke or bring any open flame close to the battery.
• Hydrogen gas is generated when the battery is being
charged, so remove the battery from the machine, take it
to a well-ventilated place, remove the battery caps, then
perform the charging.
• After charging, tighten the battery caps securely.

2-37
PRECAUTIONS FOR MAINTENANCE SAFETY

Danger from dilute sulphuric acid

When the battery is being charged, flammable hydrogen gas is
generated and may explode. In addition, the battery electrolyte
includes dilute sulphuric acid. Any mistake in handling may
cause serious personal injury, explosion, or fire. Always ob-
serve the following.
• When handling the battery, always wear protective eye-
glasses and rubber gloves.
• If battery electrolyte gets into your eyes, immediately wash
your eyes with large amounts of fresh water. After that, get
,&
medical attention immediately.
• If battery electrolyte gets on your clothes or skin, wash it
off immediately with large amounts of water.
Danger of sparks
Sparks may be generated and they can cause a fire. Always observe the following.
• Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools
lying around near the battery.
• When removing the battery cables, turn the starting switch to OFF position and, after checking that the sys-
tem operating lamp goes out, set the battery disconnect switch key to OFF position and pull it out.
When removing the battery cables, remove the ground cable (negative (-) cable) first. When installing, con-
nect the positive (+) cable first, then connect the ground.
• Tighten the battery cable terminals securely.
• Secure the battery firmly in the specified position.

PRECAUTIONS WHEN USING HAMMER

When using a hammer, pins may come out or metal particles may be scattered. It is dangerous and may cause
serious personal injury or death. Always observe the following.
• When hitting pins or bucket teeth, broken pieces may be scattered, and it may cause personal injury to the
people in the surrounding area. Always check that there is no one in the surrounding area.
• If hard metal parts such as pins, bucket teeth, cutting
edges, or bearings are hit with a hammer, pieces might be
scattered, and it may cause serious personal injury or
death. Always wear protective eyeglasses and gloves.
• If the pin is hit with strong force, it may come out, and in-
jure people in the surrounding area. Do not allow anyone
to enter the surrounding area.

,&

PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT

To prevent burns from boiling water or steam spurting out when
checking or draining the coolant, wait for the coolant to cool
down to a temperature where the radiator cap can be touched
by hand. Then loosen the cap slowly to release the pressure in-
side the radiator, and remove the cap.

2-38
SAFETY PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS FOR HIGH-TEMPERATURE OIL

To prevent burns from hot oil spurting out or from touching
high-temperature parts when checking or draining the oil, wait
for the oil to cool down to a temperature where the cap or plug
can be touched by hand. Then, loosen the cap or plug slowly to
release the internal pressure and remove the cap or plug.

PRECAUTIONS FOR HIGH-TEMPERATURE PARTS

To prevent burns from touching high-temperature parts, when checking or performing maintenance after stop-
ping engine, check the parts have been cooled down to touch with bare hand before checking or maintenance.

PRECAUTIONS FOR HIGH-PRESSURE OIL

The hydraulic system is always under internal pressure. In addition, the fuel piping is also under internal pres-
sure when the engine is running and immediately after the engine is stopped. When performing inspection or
replacement of the piping or hoses, check that the internal pressure in the circuit has been released. If this is not
done, serious personal injury or death may occur. Always observe the following.
• Do not perform inspection or replacement work with the circuit under pressure.
Release the pressure. For details, see “STOP ENGINE BEFORE CARRYING OUT INSPECTION AND
MAINTENANCE (2-34)”.
• If there is any leakage from the piping or hoses, the surrounding area may be wet, so check for cracks in
the piping and hoses and for swelling in the hoses.
When performing inspection, wear protective equipment such as protective eyeglasses and leather gloves.
• High-pressure oil leaking from small holes is dangerous
that may penetrate your skin and cause loss of sight if it
contacts your skin or eyes directly. If a jet of high-pressure
oil hit your skin or eyes, and suffer injury, wash the place
with clean water, and consult a doctor immediately for
medical attention.
• The oil pressure in the ECSS circuit is stored by the accu-
mulator. Do not remove the ECSS piping and parts.
If it is necessary to remove them, ask your Komatsu dis-
tributor to perform the removal work.

PRECAUTIONS FOR HIGH-PRESSURE FUEL

While the engine is running, high-pressure is generated in the engine fuel piping. If you try to disassemble the
piping before the internal pressure is released, serious personal injury or death can result. When performing in-
spection or maintenance of the fuel piping system, stop the engine and wait for at least 30 seconds to allow the
internal pressure to go down before starting the work.

HANDLE HIGH-PRESSURE HOSES AND PIPING

If oil or fuel leaks from high-pressure hoses or piping, it may cause fire or defective operation. It is dangerous
and may cause serious personal injury or death. If the hose or piping mounts are loose or oil or fuel is found to
be leaking from the mount, stop operations and tighten to the specified torque.
If any damaged or deformed hoses or piping are found, consult your Komatsu distributor.
Replace the hose if any of the following problems are found.
• Damaged hose or deformed hydraulic fitting.
• Frayed or cut covering or exposed reinforcement wire layer.

2-39
PRECAUTIONS FOR MAINTENANCE SAFETY

• Covering swollen in places.

• Twisted or crushed movable portion.
• Foreign material embedded in covering.

PRECAUTIONS FOR NOISE

When performing maintenance of the engine and you are exposed to noise for long periods of time, wear ear
covers or ear plugs while working.
If the noise is too loud, it may cause temporary or permanent hearing problems.

HANDLE ACCUMULATOR AND GAS SPRING

This machine is equipped with an accumulator. For a while after the engine has been stopped, if the multifunc-
tion mono-lever is operated in LOWER direction while the starting switch key is at ON position, the work equip-
ment goes down with its own weight.
After stopping the engine, turn the work equipment lock switch to LOCK position and the parking brake switch to
ON (operation) position.
The accumulator and gas spring are charged with high-pressure nitrogen gas. If the accumulator is handled
mistakenly, it may cause an explosion. It is dangerous and may cause serious personal injury or death. Always
observe the following.
• Do not disassemble.
• Do not bring it near flame or dispose of it in fire.
• Do not make holes in it, weld it, nor use a cutting torch.
• Do not hit or roll the accumulator, or subject it to any im-
pact.
• When disposing of the accumulator, the gas must be re-
leased. Ask your Komatsu distributor to perform this work.

PRECAUTIONS FOR COMPRESSED AIR

• When performing cleaning with compressed air, there is a hazard of serious personal injury or death
caused by flying dust or particles.
• When using compressed air to clean the filter element or radiator, wear protective eyeglasses, anti-dust
mask, gloves, and other protective equipment.

MAINTENANCE OF AIR CONDITIONER

If air conditioner refrigerant gets into your eyes, it may cause loss of sight; if it contacts your skin, it may cause
frostbite. Never loosen any parts of the cooling circuit.

CHEMICAL HAZARD
During maintenance or dismantling operations, where there is the risk of contact with hazardous chemical sub-
stances, relevant safety precautions should be taken.
If any doubt exists, contact your Komatsu distributor.

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.

2-40
SAFETY PRECAUTIONS FOR MAINTENANCE

• Always drain the oil from your machine in containers. Nev-

er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
batteries, and DEF.

Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.

METHOD FOR SELECTING WINDOW WASHER FLUID

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

PERIODIC REPLACEMENT OF DEFINED LIFE PARTS

• For using the machine safely for a long period, always perform periodic replacement of the defined life parts
that have a particularly close relation to safety, such as hoses and the seat belt.
Replacement of the defined life parts: See “PERIODIC REPLACEMENT OF DEFINED LIFE PARTS”.
• 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 personal
injury or death. 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 the defined life parts if any defect is found, even when they have not reached the speci-
fied replacement time.

TIRES
HANDLE TIRES
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 personal injury or death.
To ensure safety, always observe the following.
• Maintenance, disassembly, repair, and assembly of the
tires and rims requires special equipment and special tech-
nology, so always ask your Komatsu distributor to perform
these operations.
• Use only specified tires and inflate them to the specified
pressure.
• When pumping up the tires, check that no other person is
standing near the tire, and install an air chuck with a clip
that can be secured to the air valve.
To prevent the tire inflation pressure from becoming too
high, measure the pressure from time to time with an air
gauge while pumping up the tire.
• If the tire inflation pressure goes down abnormally or the
rim parts do not fit the tire, there is a problem with the tire
or rim parts. Always contact your Komatsu distributor for
repairs.

2-41
PRECAUTIONS FOR MAINTENANCE SAFETY

• If the rim parts are not fitted properly when the tire is being pumped up, there is a danger that the rim parts
may fly off, so set up a protective fence around the tire, and do not stand directly in front of the rim. Stand
beside the tread when pumping up the tire.
• Do not adjust the tire inflation pressure immediately after traveling at high speed or operating under heavy
load.
• Never perform welding or light a fire near the tire.
• Always release the inflation pressure from a tire prior to removing rim from tire.
• Before removing the tire from the machine for repairs, remove the valve partially to release the air from the
tire gradually, then remove the tire.

PRECAUTIONS FOR STORING TIRES

Tires for construction equipment are extremely heavy, it may
lead to serious personal injury or death. To maintain safety, al-
ways observe the following.
• As a basic rule, store the tires in a warehouse which unau-
thorized persons cannot enter.
If the tires must be stored outside, always erect a fence
and put up “No Entry” signs.
• Stand the tire at the angle of 60 to 70 ° (A) on a level
ground, and block it securely (1) so that it cannot tip over
or fall over if any person should touch it. Do not lay the tire
on its side. This will deform the tire and cause it to deterio-
rate.
• If the tire should fall over, do not attempt to stop it. Get out of the way quickly.

2-42
SAFETY PRECAUTIONS FOR DEF

PRECAUTIONS FOR DEF

GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is
used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im-
mediate action:
• If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off
and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or
begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear
rubber gloves when you perform work handling DEF to avoid skin contact.

PRECAUTIONS FOR ADDING

Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a
fire. Some fluids or agents added can create and emit a toxic gas.
When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face away from
the filler port during opening or refilling.

PRECAUTIONS FOR STORING

If the temperature of DEF becomes high, a harmful ammonia gas may be emitted. Completely seal up its con-
tainer for storage. Only open containers in a well-ventilated area.
When storing DEF, avoid direct sunlight. Always use the original container it came in. Do not exchange the con-
tainer of DEF with another one. If DEF is stored in an iron or aluminum container, toxic gas may develop and a
chemical reaction may corrode the container.

PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas.
If DEF is spilled, immediately wash and clean the area with water. If spilled DEF is left unattended and the area
is not washed and cleaned, it can cause corrosion to the contaminated area and emit toxic gas.

OTHER PRECAUTIONS
When disposing of DEF, treat it as an industrial waste. The container for DEF is an industrial waste as well. It
should be treated in the same way.
Never use an iron or aluminum container when disposing DEF, because toxic gas may develop and a chemical
reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when handling the
fluid waste of DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel
or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
White powder (crystallized urea) may cover the exhaust pipe outlet of aftertreatment devices. When you wipe off
the covered materials, discard the crystallized urea and the used cloth as industrial waste.
Never relocate or modify the exhaust gas aftertreatment devices. The harmful gas may be exhausted and it can
cause serious damage to the environment as well as violation of laws.

2-43
 OPERATION

Please read and make sure that you understand the SAFETY section before
reading this section.

3-1
GENERAL VIEW OPERATION

GENERAL VIEW
MACHINE EQUIPMENT NAME

(1) Bucket (11) Rear wheel

(2) Front wheel (12) Stepladder
(3) Bell crank (13) Lift cylinder
(4) Bucket cylinder (14) Boom
(5) Turn signal lamp (15) Rear working lamp
(6) Headlamp (16) Rearview camera
(7) Rearview mirror (17) Rear combination lamp
(8) Front working lamp (18) Rear full-length fender
(9) ROPS cab (19) Chock (if equipped)
(10) Auto-greasing

3-2
OPERATION GENERAL VIEW

CONTROLS AND GAUGES NAMES

(1) Front switch panel (9) Turn signal lever

(2) Directional lever (9) Dimmer switch
(3) Engine shutdown secondary switch (10) Parking brake switch
(4) Hazard lamp switch (11) Monitor switch
(5) Speed range selector switch (12) Cigarette lighter
(6) Machine monitor (12) 24 V power supply
(7) Steering wheel (13) Rearview monitor brightness adjustment switch
(8) Horn switch (14) Rearview monitor
(9) Lamp switch (15) Work equipment lock switch

3-3
GENERAL VIEW OPERATION

(16) R.H. switch panel (24) Rear wiper switch

(17) Directional selector switch (25) Steering tilt lock lever
(18) Multifunction mono-lever (26) L.H. brake pedal
(19) PCS (Proportional Control Switch) (if equipped) (27) Max. traction switch
(20) Accelerator pedal (28) Room lamp switch
(21) R.H. brake pedal (29) Rear heated wire glass switch
(22) Starting switch (30) Emergency HST pump drive switch
(23) Front wiper switch

SWITCH PANEL

Front switch panel

(1) Front working lamp switch (4) Monitor brightness selector switch
(2) Rear working lamp switch (5) ECSS switch
(3) Beacon lamp switch (if equipped) (6) Quick coupler attachment switch (if equipped)
R.H. switch panel
(7) Travel speed control dial (10) Attachment selector switch (if equipped)
(8) Traction control switch (11) Remote positioner switch
(9) Directional selector switch actuation switch (12) 2-stage low idle switch
* ECSS: Electronically Controlled Suspension System

3-4
OPERATION GENERAL VIEW

MACHINE MONITOR EQUIPMENT NAME

General view

(A) LCD unit (C) Meter unit

(B) LED unit
(1) HST oil temperature gauge (15) Engine tachometer
(2) HST oil temperature caution lamp (16) Speedometer
(3) Engine coolant temperature caution lamp (17) Fuel level caution lamp
(4) Engine coolant temperature gauge (18) Fuel gauge
(5) ECO gauge (19) Variable speed display
(6) Air conditioner display (20) DEF level gauge
(7) Clock (21) R.H. meter (Select the fuel consumption gauge,
(8) Centralized warning lamp service meter, odometer, or clock.)
(9) Parking brake pilot lamp (22) L.H. meter (Select the service meter, odometer, or
clock.)
(10) Turn signal pilot lamp (L.H.)
(23) DOWN switch
(11) Headlamp (high beam) pilot lamp
(24) UP switch
(12) Turn signal pilot lamp (R.H.)
(25) ENTER switch
(13) Brake oil pressure caution lamp
(26) RETURN switch
(14) Clearance lamp pilot lamp

3-5
GENERAL VIEW OPERATION

Display of liquid crystal unit

(A) Standard screen (D) Warning screen

(B) ECO guidance screen (E) User menu screen
(C) Maintenance time warning screen
(27) Message display (37) Preheating pilot lamp
(28) Quick coupler lock release pilot lamp (if equipped) (38) Fan reverse rotation display
(29) Directional selector pilot lamp (39) Secondary steering pilot lamp
(30) ECSS pilot lamp (40) Aftertreatment devices regeneration display
(31) 2-stage low idling pilot lamp (41) Guidance display
(32) Traction level (42) Maintenance time caution lamp
(33) Shift indicator position display (43) Guidance icon
(34) Work equipment lock pilot lamp (44) Seat belt caution lamp
(34) Remote positioner pilot lamp (45) Warning display
(35) Steering low oil pressure caution lamp (if equip- (46) Action level display
ped)
(36) Emergency HST pump drive pilot lamp
* At place (34), 2 types of pilot lamp are prepared.

3-6
OPERATION GENERAL VIEW

OTHER EQUIPMENT NAME

Inside of cab

(1) Cigarette lighter (7) Open lock for cab L.H. door
(1) 24 V power supply (8) Cab door handle
(2) Rearview monitor (9) Fuse
(3) Ashtray (10) AUX
(4) Open knob for alternate exit of cab (11) Unlock knob for slide window of cab
(5) Cool box (12) Open handle for cab L.H. door
(6) Cup holder (13) 12 V power supply

3-7
GENERAL VIEW OPERATION

Outside of cab

(1) Slow-blow fuse (2) Frame lock bar

3-8
OPERATION GENERAL VIEW

(3) Towing pin (10) Battery disconnect switch

(4) Backup alarm (11) System operating lamp
(5) KDPF (12) DEF pump
(6) DEF injector (13) DEF filter
(7) SCR assembly (14) DEF tank
(8) Dust indicator
(9) Komatsu Closed Crankcase Ventilation (hereafter
KCCV) ventilator

3-9
EXPLANATION OF COMPONENTS OPERATION

EXPLANATION OF COMPONENTS
The following is an explanation of devices necessary to operate the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operat-
ing the equipment, and the meanings of the displays.

EXPLANATION OF MACHINE MONITOR EQUIPMENT

FF: Failure display screen

(A) Warning display (C) Meter display
(B) Pilot display (D) Monitor switch area

3-10
OPERATION EXPLANATION OF COMPONENTS

BASIC OPERATION OF MACHINE MONITOR

BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR-
MAL SITUATION

When the starting switch is turned to ON position, the machine monitor starts and operates as follows.
1. Centralized warning lamp (A) and pilot lamp (B) light up for 2 seconds and go out for 1 second.
2. Liquid crystal display (C) displays starting screen AA for 2 seconds, and then changes to standard screen
BB.
3. The pointer of engine tachometer (D) swings once.
4. Speedometer (E) displays “88” for 2 seconds.
5. The alarm buzzer sounds for 2 seconds, then stops under the normal condition.
NOTICE
If the lamps, alarm buzzer, etc. do not work, the machine monitor may be failed or the electric wiring
may have breakage. In this case, ask your Komatsu distributor for repair.
REMARK
When the engine is started, the battery voltage may suddenly drop depending on the temperature and the bat-
tery condition.
In such case, the machine monitor may go out temporarily or restart, but it is not a trouble.

3-11
EXPLANATION OF COMPONENTS OPERATION

BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE

ENGINE SHUTDOWN SECONDARY SWITCH IS ON
While engine shutdown secondary switch (1) is ON (engine
stopped), even if the starting switch is turned to ON position,
the screen shown in the figure is displayed and the engine
does not start.
When engine shutdown secondary switch (1) is turned OFF
(normal), the machine monitor returns to the standard screen,
and the engine can be started with usual starting switch opera-
tion.

BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR-

MAL SITUATION

When starting switch is turned to OFF position, the screen goes out. In the following case, the end screen is
displayed for 5 seconds, and then screen goes out.
End screen with message
If there is any message from your Komatsu distributor, it is displayed on end screen DD for 5 seconds, and then
the screen goes out.
In this case, turn the starting switch to ON position to re-check the message, and if it is the message requesting
response, send back your reply.

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OPERATION EXPLANATION OF COMPONENTS

End screen with “Operational Advice”

If there is any “Operational Advice” , “Operational Advice” is displayed on end screen EE for 5 seconds, and
then the screen goes out.

BASIC OPERATION OF MACHINE MONITOR WHEN STARTING SWITCH IS ON

WHILE OPERATOR ID INPUT IS SET

• If inputting ID number for operator identification function (with SKIP) is set, the opening screen AA switches
to ID number input screen LL (with SKIP) when the starting switch is turned to ON position.
• If inputting ID number for operator identification function (without SKIP) is set, the opening screen AA
switches to ID number input screen MM (without SKIP) when the starting switch is turned to ON position.
• On the ID number input screen LL (with SKIP) or MM
(without SKIP), input the already registered ID number,
and press ENTER switch (1). The screen changes to the
Check Before Starting screen BB. If you input an incorrect
ID number, press RETURN switch (2), and clear an input
character at a time.
On the ID number input screen LL (with SKIP), press
menu switch (3), and the screen changes to the Check Be-
fore Starting screen BB without inputting ID number.

REMARK
• Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator
identification function.
• Depending on the set value of ID holding time, even if inputting ID number for operator identification func-
tion is set, the ID number input screen LL (with SKIP) or MM (without SKIP) may not be displayed while the
starting switch is turned to ON position.
If inputting incorrect ID number for 3 times continuously, you cannot input ID number for 5 minutes. Wait for
more than 5 minutes, try inputting ID number again.
As long as ID number input screen is displayed, the engine cannot be started. If you forget the ID number and
cannot start the engine, confirm the person in charge of the machine.

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EXPLANATION OF COMPONENTS OPERATION

NOTICE
Since the purpose of the operator identification function is neither security enhancement nor a protec-
tion against theft, it has no antitheft effect. Be careful not to use it for the purpose of security enhance-
ment.
Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or
unauthorized use of ID by a third person.

BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN AB-

NORMAL SITUATION

When the machine monitor is started, if the machine has trou-

ble, starting screen AA is displayed for 2 seconds and then it is
changed to the failure display screen FF.
When ENTER switch displayed in guidance icon (1) is pressed,
the “Current Abnormality” screen is displayed.

When the machine monitor is started, if the time to the next

maintenance of any item is 30 hours or less, starting screen AA
is displayed for 2 seconds and then it is changed to mainte-
nance time warning screen GG.
When the menu switch displayed in guidance icon (2) is press-
ed, the “Maintenance” menu screen is displayed.
After displaying maintenance time warning screen GG for 30
seconds, the screen returns to the standard screen BB.

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OPERATION EXPLANATION OF COMPONENTS

BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE

OPERATING MACHINE

If any trouble occurs during operation, the standard screen BB

changes to the failure display screen FF.
When ENTER switch is pressed while guidance icon (1) is dis-
played, the “Current Abnormality” screen is displayed.
REMARK
Guidance icon (1) is displayed only while the machine is stop-
ped completely.
Even when ENTER switch is pressed while the machine is not
stopped completely, the “Current Abnormality” screen is not
displayed.

WARNING DISPLAY
NOTICE
The machine has a trouble if any of the action levels “L01” to “L04” is displayed on the machine moni-
tor.
Take appropriate actions following “List of action level displays and required actions”.
• These caution lamps do not guarantee the condition of the machine.
Do not simply rely on the monitor when performing checks before starting (daily inspection). Al-
ways get off the machine and check each item directly.
• When the caution lamp is displayed in red, if no action is taken, the machine can be seriously affect-
ed. Accordingly, take proper actions immediately.
• The engine output or engine speed is limited and the machine operation speed may become slow,
depending on the contents of the warning.

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EXPLANATION OF COMPONENTS OPERATION

(1) HST oil temperature caution lamp (7) Seat belt caution lamp
(2) Engine coolant temperature caution lamp (8) Action level
(3) Warning display (9) Brake oil pressure caution lamp
(4) Warning display (10) Fuel level caution lamp
(5) Centralized warning lamp (11) DEF level caution lamp
(6) Guidance icon

ACTION LEVEL DISPLAY

Action level display indicates the degree of urgency of the ab-
normality currently generated on the machine by “L01” to “L04”.
The larger the number in the table is, the more serious effects
the abnormality may have on the machine if it is left with no ac-
tion.
When the machine monitor displays an action level, take ap-
propriate actions according to “List of action level displays and
required actions”.

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OPERATION EXPLANATION OF COMPONENTS

List of action level displays and required actions

Degree of Action Centralized Caution
Buzzer Required action
urgency level warning lamp lamp
Sounds Stop the machine immediately and ask your Ko-
Lights up
L04 Lights up continuous- matsu distributor for inspection and maintenance.
in red
ly
Stop the operation and move the machine to a
Sounds in- Lights up
L03 Lights up safe place, then ask your Komatsu distributor for
termittently in red
inspection and maintenance.
High If there is an overrun related display, reduce the
↑ engine speed and machine travel speed while
continuing operations.
│
If there is an overheat related display, stop the
│
machine at a safe place, and run the engine at
│ Sounds in- Lights up medium speed with no load.
L02 Lights up
│ termittently in red If there is a secondary steering related display,
│ avoid a long time usage of the secondary steer-
ing.
↓
If the condition is not improved, check the failure
Low
code and ask your Komatsu distributor for in-
spection and maintenance.
Some functions may be restricted from use, but
the machine can operate. When you finish the
Does not Lights up
L01 OFF operation, always have the inspection and main-
sound in yellow
tenance performed. Ask your Komatsu distributor
for the inspection and maintenance as needed.

REMARK
• When the action level display is “L01”, “L01” is displayed
only for 2 seconds, and then it is turned OFF.
• If plural failures occur at the same time, the action level
with the highest urgency (the greatest number) is dis-
played.

CURRENT ABNORMALITY LIST DISPLAY

The monitor provides information on failures that occurred on the machine and necessary remedies for action
levels that are displayed.
When ENTER switch is pressed while the guidance icon is displayed, the screen changes to the “Current Ab-
normality” screen.

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EXPLANATION OF COMPONENTS OPERATION

Take appropriate remedies according to the message displayed

on the monitor.
REMARK
The guidance icon is displayed only while the machine is stop-
ped completely.
Even when ENTER switch is pressed while the machine is not
stopped completely, the “Current Abnormality” screen is not
displayed.

(A) Caution lamp

(B) Action level
(C) Failure code
Code to indicate the content of the failure. Notify it when calling your Komatsu distributor.
(D) Failure name
(E) Message
Take appropriate remedies according to the displayed message.
(F) Contact telephone number
The telephone number of the contact such as your Komatsu distributor is displayed.
If no point of contact telephone number is registered, no telephone number is displayed.
Ask your Komatsu distributor for the telephone number registration if necessary.

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OPERATION EXPLANATION OF COMPONENTS

(G) Guidance icon

On the “Current Abnormality” list screen, the following switches displayed in guidance icon (G) can be operated.
UP switch: Moves to the previous page. When on the first
page, it moves to the last page.

DOWN switch: Moves to the next page. When on the last page,
it moves to the first page.

RETURN switch: Returns to the standard screen.

ENGINE COOLANT TEMPERATURE CAUTION LAMP

Engine coolant temperature caution lamp warns about over-
heating of the engine coolant.
If the engine coolant temperature is abnormally high, the cau-
tion lamp lights up in red and action level “L02” is displayed.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
Stop the machine in a safe place, set the directional lever and
directional selector switch to NEUTRAL position (N), and run
the engine at a medium speed with no load until the caution
lamp goes out.

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EXPLANATION OF COMPONENTS OPERATION

FUEL LEVEL CAUTION LAMP

The fuel level caution lamp warns about low remaining fuel lev-
el.
The lamp lights up in red if the fuel level is 33 ℓ or below.
Add fuel as soon as possible.

HST OIL TEMPERATURE CAUTION LAMP

The HST oil temperature caution lamp warns about overheat-
ing of the HST oil.
If the HST oil temperature increases abnormally high, the cau-
tion lamp lights up in red and action level “L02” is displayed.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
Stop the machine in a safe place, set the directional lever and
directional selector switch to NEUTRAL position (N), and run
the engine at a medium speed with no load until the caution
lamp goes out.
If the HST oil temperature becomes less than 10 °C, the caution lamp is lit in white, and the travel speed accel-
eration is limited.
Run the engine at low idle until the caution lamp goes out.
REMARK
The setting to increase the engine low idle speed under the low ambient temperature is available. For details,
see “2-STAGE LOW IDLE SWITCH”.

BRAKE OIL PRESSURE CAUTION LAMP

The brake oil pressure caution lamp warns that the brake oil
pressure is below the specified value.
When action level “L03” is displayed
If the brake oil pressure drops below the specified value while
the engine is running, the caution lamp lights up in red.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, stop the
engine, then ask your Komatsu distributor for inspection and
maintenance.
Action level is not displayed and lamp lights up in red
If the brake oil pressure is below the specified value while the engine is stopped, the caution lamp lights up in
red.
When the engine is started, the caution lamp lights up in red until the brake oil pressure rises above the speci-
fied value.
At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently.
Wait until the caution lamp goes out, and then start the machine.

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OPERATION EXPLANATION OF COMPONENTS

SYSTEM CAUTION LAMP

The system caution lamp warns about abnormality in the sys-
tem.
When action level “L03” is displayed
The caution lamp lights up in red.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, stop the
engine, then ask your Komatsu distributor for inspection and
maintenance.
When action level “L01” is displayed
The caution lamp lights up in yellow.
When you finish the operation, always perform the inspection and maintenance.
Ask your Komatsu distributor for the inspection and maintenance as needed.

WORK EQUIPMENT SYSTEM CAUTION LAMP

The work equipment system caution lamp warns about abnor-
mality in the work equipment system.
When action level “L03” is displayed
The caution lamp lights up in red.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, stop the
engine, then ask your Komatsu distributor for inspection and
maintenance.
When action level “L01” is displayed
The caution lamp lights up in yellow.
When you finish the operation, always perform the inspection and maintenance.
Ask your Komatsu distributor for inspection and maintenance as needed.

BRAKE OIL TEMPERATURE CAUTION LAMP

The brake oil temperature caution lamp warns about overheat-
ing of the brake oil.
If the machine is operated continuously under severe condition
or the brake is used frequently on a long downhill slope, the
brake oil temperature increases.
If the caution lamp lights up in yellow, perform the following ac-
tions.
1. Release the accelerator pedal to decrease the speed.
2. Avoid frequent use of the brake.
Do not continue depressing the brake pedal but depress it
intermittently.
When the machine is operated with the brake used less frequently as described above for a while, the brake oil
temperature decreases and the caution lamp goes out.

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EXPLANATION OF COMPONENTS OPERATION

DEF LEVEL CAUTION LAMP

DEF level caution lamp alerts when DEF tank level becomes
low.
Whenever the caution lamp lights up in red, immediately add
DEF.
Fault conditions that result in activation of the Inducement strat-
egy for engine derates to prompt to maintain or repair the emis-
sion control system.
When Lightning in red,
With Action level “L04”, DEF tank level is too low. Inducement
status is “Severe Inducement”. Engine power is under heavy
deration.
With Action level “L03”, DEF tank level is low. Inducement status is “Low level Inducement”. Engine power is
under deration.
With No Action level display.DEF tank level is lower. Inducement status is “Continuous Warning”. Need to add
DEF immediately to avoid advancing to the next Inducement status.
With No Action level display. Warning starts. Inducement status is “Warning”. Need to add DEF immediately.
When Lightning in white
When fluctuation of DEF tank level is large, frozen, or not limited to, tank level sensing is not performed correct-
ly.
When DEF is added after engine starting switch turn to OFF.
When DEF tank level sensor is defective.
REMARK
For more information about the Inducement strategy, and Inducement status concerning engine power deration,
see “HANDLE UREA SCR SYSTEM WARNING (3-135)”.

SEATBELT CAUTION LAMP

The seat belt caution lamp lights up when the seat belt is not
fastened.
Always fasten the seat belt while traveling because there may
be a possible danger.

DIRECTIONAL SWITCH CAUTION LAMP

The directional switch caution lamp warns the operator that
there is wrong operation of the directional selector switch or di-
rectional lever.
If the caution lamp lights up in red, return the directional selec-
tor switch and directional lever to NEUTRAL position (N).

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OPERATION EXPLANATION OF COMPONENTS

WARNING DISPLAY
The caution lamps displayed on the warning display section are
as follows. Take appropriate measures according to the speci-
fied remedies.
REMARK
• When 1 type of alarm is generated, it is displayed on cau-
tion lamp (A).
• When 2 types of alarm are generated, they are displayed
on caution lamps (A) and (B).
• When 3 types of alarm are generated, they are displayed
on caution lamps (A) and (B) alternately at intervals of 2
seconds.

STEERING OIL PRESSURE CAUTION LAMP

The steering oil pressure caution lamp warns the operator that
the steering oil pressure is below the specified value.
If the engine oil pressure drops below the specified value while
the engine is running, the caution lamp lights up in red and the
action level “L03” is displayed.
At the same time, the centralized warning lamp lights up and
the alarm buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, stop the
engine, then ask your Komatsu distributor for the inspection
and maintenance.

HST SYSTEM CAUTION LAMP

HST system caution lamp warns about abnormality in the HST
system.
When action level “L03” is displayed
The caution lamp lights up in red.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, stop the
engine, then ask your Komatsu distributor for inspection and
maintenance.
When action level “L01” is displayed
The caution lamp lights up in yellow.
When you finish the operation, always perform the inspection and maintenance.
Ask your Komatsu distributor for the inspection and maintenance as needed.

HST OIL FILTER CLOGGING CAUTION LAMP

HST oil filter clogging caution lamp warns about clogging of the
HST oil filter.
When clogged
The caution lamp lights up in yellow, and action level “L01” is
displayed.
Replace the oil filter by referring to “METHOD FOR REPLAC-
ING HST OIL FILTER CARTRIDGE (4-61)”.

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EXPLANATION OF COMPONENTS OPERATION

KDPF SYSTEM CAUTION LAMP

The KDPF system caution lamp warns about abnormality in the
KDPF system.
When action level “L04” is displayed
The caution lamp lights up in red.
At the same time, the centralized warning lamp lights up and
the alarm buzzer sounds continuously.
Stop the machine immediately and ask your Komatsu distribu-
tor for inspection and maintenance.
When action level “L03” is displayed
The caution lamp lights up in red.
At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for
inspection and maintenance.
When action level “L01” is displayed
The caution lamp lights up in yellow.
When you finish the operation, always perform the inspection and maintenance.
Ask your Komatsu distributor for the inspection and maintenance as needed.
REMARK
If you ignore the caution lamp and continue the work, the peripheral temperature of the aftertreatment devices
may increase abnormally.
For the aftertreatment devices, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-126)”.

KDPF SOOT ACCUMULATION CAUTION LAMP

The KDPF soot accumulation caution lamp warns that soot is
accumulated in KDPF or the filtering function of KDPF has low-
ered abnormally.
When action level “L03” is displayed
The caution lamp lights up in red if much soot is accumulated
in KDPF or a system trouble such as lowering of the filtering
function of KDPF occurs.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, and per-
form the manual stationary regeneration.
The manual stationary regeneration may start automatically to protect the KDPF system.
When action level “L01” is displayed
The caution lamp lights up in yellow if much soot is accumulated in KDPF.
After the operation is finished, move the machine to a safe place and perform manual stationary regeneration.
REMARK
For details of the manual stationary regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF)
(3-126)”.

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OPERATION EXPLANATION OF COMPONENTS

DEF SYSTEM CAUTION LAMP

DEF system caution lamp alerts when abnormality in the sys-
tem are detected.
Whenever the caution lamp lights up in yellow or in red, take
necessary actions by instructions.
Fault conditions that result in activation of the Inducement strat-
egy for engine derates to prompt to maintain or repair the emis-
sion control system.
Lighting in red
With Action level “L04”, Inducement status is “Severe Induce-
ment”. Engine power is under heavy deration.
With Action level “L03”, Inducement status is “Low level Inducement”. Engine power is under deration.
Lighting in yellow
With Action level “L01”, Inducement status is “Warning” or “Continuous Warning”.
When “Continuous Warning”, If no maintenance, advancing to the next Inducement status. Engine power will be
derated.
REMARK
For more information about the Inducement strategy, and Inducement status concerning engine power deration,
see “HANDLE UREA SCR SYSTEM WARNING (3-135)”.

DEF SYSTEM HIGH TEMPERATURE STOP CAUTION LAMP

DEF system high temperature stop caution lamp alerts when
the times of engine is shut down under the condition of high de-
gree temperature of DEF system exceeds the defined number
of times.
Whenever the caution lamp lights up in yellow, it is necessary
to ask your Komatsu distributor to go off this caution lamp.
When stopping the engine, stop it after running it at low idle for
approximately 5 minutes. For details, see “METHOD FOR
STOPPING ENGINE (3-183)”.
When stopping the engine during the aftertreatment devices re-
generation, stop the regeneration first according to “PROCE-
DURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING (3-132)”, then stop the en-
gine after running it at low idle for approximately 5 minutes.

ENGINE SYSTEM CAUTION LAMP

k WARNING
If the operation is continued while the caution lamp is lit in red, accumulation and combustion of the
soot in KDPF are accelerated, and consequently the temperature of KDPF and exhaust gas can increase
high. Stop the engine immediately.

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EXPLANATION OF COMPONENTS OPERATION

The engine system caution lamp warns about abnormality in

the engine system.
When action level “L04” is displayed
The caution lamp lights up in red. At the same time, the central-
ized warning lamp lights up and the alarm buzzer sounds con-
tinuously.
Immediately stop the machine and ask your Komatsu distribu-
tor for inspection and maintenance.
When action level “L03” is displayed
The caution lamp lights up in red. At the same time, the central-
ized warning lamp lights up and alarm buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for
inspection and maintenance.
When action level “L01” is displayed
The caution lamp lights up in yellow.
When you finish the operation, always perform the inspection and maintenance.
Ask your Komatsu distributor for the inspection and maintenance as needed.

ENGINE OIL PRESSURE CAUTION LAMP

Engine oil pressure caution lamp warns about low engine lubri-
cating oil pressure.
If the engine oil pressure drops below the specified value while
the engine is running, the caution lamp lights up in red and ac-
tion level “L03” is displayed.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, stop the
engine, then ask your Komatsu distributor for inspection and
maintenance.

ENGINE OIL LEVEL CAUTION LAMP

Engine oil level caution lamp warns about drop of engine lubri-
cating oil level. It displays only while the engine is stopped.
If the caution lamp lights up in yellow and action level “L01” is
displayed, inspect the oil level in the oil pan and add oil.
See “METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL
PAN, ADDING OIL (3-156)”.
If it occurs again in a short time, the engine oil may be leaking.
Ask your Komatsu distributor for inspection and maintenance.

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OPERATION EXPLANATION OF COMPONENTS

ENGINE OVERRUN CAUTION LAMP

The engine overrun caution lamp warns the operator that the
engine speed is higher than the allowable range.
When the caution lamp lights up in red, the centralized warning
lamp lights up and the alarm buzzer sounds intermittently.
If the engine speed increases more, action level “L02” is dis-
played.
Operate the machine with moderate engine speed and travel
speed.

RADIATOR COOLANT LEVEL CAUTION LAMP

Radiator coolant level caution lamp warns about drop of radia-
tor coolant level.
If the caution lamp lights up in yellow and action level “L01” is
displayed, inspect the coolant level in the reservoir tank and
add coolant.
See “METHOD FOR CHECKING COOLANT LEVEL, ADDING
COOLANT (3-156)”.
If it occurs again in a short time, the coolant may be leaking
from the radiator. Ask your Komatsu distributor for inspection
and maintenance.

CHARGE LEVEL CAUTION LAMP

Charge level caution lamp warns about abnormality in the
charging system while the engine is running.
If the battery is not charged properly while the engine is run-
ning, the caution lamp lights up in red.
At the same time, action level “L03” is displayed and the cen-
tralized warning lamp lights up and the alarm buzzer sounds in-
termittently.
Stop the engine and check the alternator belt for damage, then
ask your Komatsu distributor for inspection and maintenance.

WATER SEPARATOR CAUTION LAMP

The water separator caution lamp warns that water is accumu-
lated in the water separator.
When water is accumulated in the water separator, the caution
lamp lights up in red.
Stop the engine and drain water from the water separator.
For details, see “METHOD FOR CHECKING WATER SEPARA-
TOR, DRAINING WATER AND SEDIMENT (3-154)”.
REMARK
The water separator forms one unit with the fuel prefilter.
The water separator is installed at the bottom of the fuel prefil-
ter as detachable condition.

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EXPLANATION OF COMPONENTS OPERATION

AIR CLEANER CLOGGING CAUTION LAMP

Air cleaner clogging caution lamp warns about clogging of the
air cleaner.
If the caution lamp lights up in yellow and action level “L01” is
displayed, stop the engine, then inspect and clean the air
cleaner.
See “METHOD FOR CHECKING, CLEANING AND REPLAC-
ING AIR CLEANER”.

FAN CONTROL SYSTEM CAUTION LAMP

The fan control system caution lamp warns about abnormality
in the fan control system.
If the caution lamp lights up in yellow and action level “L01” is
displayed, always perform inspection and maintenance after
the operation is finished.
Ask your Komatsu distributor for the inspection and mainte-
nance as needed.

AIR CONDITIONER SYSTEM CAUTION LAMP

Air conditioner system caution lamp warns about abnormality in
air conditioner system.
If the caution lamp lights up in yellow and action level “L01” is
displayed, always perform inspection and maintenance after
the operation is finished.
Ask your Komatsu distributor for the inspection and mainte-
nance as needed.

MAINTENANCE TIME CAUTION LAMP

Maintenance time caution lamp displays the notices and alarms
concerning maintenance time.
This lamp lights up when the starting switch is turned to ON po-
sition. It goes out after 30 seconds and the screen changes to
the standard screen.
When lamp lights up in red
The maintenance due time is over.
If no action is taken, the machine performance will become
worse and the machine life will be shortened.
Perform necessary maintenance as soon as possible.
When lamp lights up in yellow
The maintenance time is approaching.
Prepare the necessary parts for the maintenance.

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OPERATION EXPLANATION OF COMPONENTS

REMARK
• To check the items that need maintenance, see “Maintenance” menu screen.
• On the standard screen, when the menu switch is pressed while the caution lamp is lit, the screen changes
directly to “Maintenance” menu screen.
• For operations on “Maintenance” menu screen, see “MAINTENANCE SCREEN SETTING”.
• By default, the maintenance time caution lamp (yellow) is set to light up when the remaining time reaches
30 hours. However, you can change this setting. To change the setting, ask your Komatsu distributor.

CENTRALIZED WARNING LAMP

The centralized warning lamp lights up in red and at the same
time the alarm buzzer sounds intermittently when the machine
is under the following condition.

Machine conditions under which centralized warn- Other monitor displays

ing lamp lights up
When action level L02, L03, or L04 is displayed on
the machine monitor.

When the engine overrun caution lamp is lit.

When the brake oil pressure is below the specified The brake oil pressure caution lamp lights
value while the engine is running. up.

When starting switch is turned to ON position while The current speed range flashes.
the directional lever and directional selector switch
are not in NEUTRAL position (N).
When all the signals from the directional lever and
directional selector switch are turned off.
When the directional lever and directional selector -
switch are not in NEUTRAL position (N) while the
parking brake is applied.
When the speed range selector switch is operated -
to the speed range of 1st or 2nd during the travel
at the speed range of 3rd or 4th.
When the directional change operation is per- -
formed during the high speed travel at the speed
range of 3rd or 4th.

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EXPLANATION OF COMPONENTS OPERATION

Machine conditions under which centralized warn- Other monitor displays

ing lamp lights up
When the directional lever is not in NEUTRAL po- The directional switch caution lamp lights up
sition (N) while the directional selector switch is ef- in red.
fective.

When the travel speed exceeds the speed limit -

and the overrun prevention control is actuated.

PILOT DISPLAY
The pilot display at the top of the screen consists of the pilot lamps to check the actuation of each function.
When the starting switch is turned on and the display items are functioning, the pilot lamps light up.

(1) Message display (6) Parking brake pilot lamp

(2) Directional selector pilot lamp (7) Traction level display
(3) ECSS pilot lamp (8) Turn signal pilot lamp
(4) Air conditioner display (9) Headlamp (high beam) pilot lamp
(5) Clock (10) 2-stage low idling pilot lamp

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OPERATION EXPLANATION OF COMPONENTS

(11) Clearance lamp pilot lamp (16) Preheating pilot lamp

(12) Work equipment lock pilot lamp (17) Fan reverse rotation display
(12) Remote positioner display (18) Secondary steering pilot lamp
(13) Shift lever position display (19) Aftertreatment devices regeneration display
(14) Steering low oil pressure caution lamp (if equip- (20) ECO guidance
ped) (21) DEF low level guidance
(15) Emergency HST pump drive pilot lamp
* At place (12), 2 types of pilot lamp are prepared.
Pop up display
For some pilot lamps, pop-up (A) is displayed on the screen
when they are selected.
See the details of the pilot lamps shown below.

TURN SIGNAL PILOT LAMP

The turn signal pilot lamp flashes synchronously with the turn
signal lamp, when it is turned on.

HEADLAMP (HIGH BEAM) PILOT LAMP

The headlamp (high beam) pilot lamp lights up when the head-
lamps are set to high beam.

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EXPLANATION OF COMPONENTS OPERATION

CLEARANCE LAMP PILOT LAMP

The clearance lamp pilot lamp lights up when the clearance
lamps are turned on.

DIRECTIONAL SELECTOR PILOT LAMP

The directional selector pilot lamp lights up in green when the
directional selector switch is effective.
It lights up in yellow when the directional selector switch is op-
erated wrongly.
It pops up when the directional selector switch actuation switch
is turned on.

ECSS PILOT LAMP

The ECSS pilot lamp lights up when ECSS is effective.
When ECSS switch is turned ON, the display pops up.

2-STAGE LOW IDLING PILOT LAMP

The 2-stage low idling pilot lamp lights up when the 2-stage low
idling is effective.

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OPERATION EXPLANATION OF COMPONENTS

REMOTE POSITIONER PILOT LAMP

The remote positioner pilot lamp lights up in green when the re-
mote positioner is effective.
When the remote positioner function is changed from OFF to
ON, the display pops up.
The remote positioner does not operate when the boom detent
function is set to OFF.
For details of the boom detent, see “BOOM RAISE DETENT
SETTING (3-67)”.
For details of the remote positioner, see “REMOTE POSITION-
ER (3-201)”.

FAN REVERSE ROTATION DISPLAY

When the radiator fan is set in manual or auto reverse rotation
mode, if the fan starts to rotate in reverse, fan reverse rotation
pilot lamp (A) lights up.
This lamp flashes while the rotation direction is being changed.
If the condition for changing the fan rotation direction is not sat-
isfied, changing condition satisfaction waiting pilot lamp (B)
lights up.
For details of the method of setting the fan reverse mode, see
“RADIATOR FAN MANUAL REVERSE MODE (3-59)” and
“RADIATOR FAN AUTOMATIC REVERSE MODE (3-61)”.

PREHEATING PILOT LAMP

The preheating pilot lamp lights up when the automatic pre-
heating function of the engine is actuated, and goes out when
preheating is completed.
The pilot lamp also lights up during manual preheating. The
electrical heater for engine preheating is actuated while the pi-
lot lamp is lit.

AIR CONDITIONER DISPLAY

The air conditioner display shows the operating state of the air
conditioner.

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EXPLANATION OF COMPONENTS OPERATION

MESSAGE DISPLAY
The message display lights up when there is a message from
Komatsu.
(A): There is unread message
(B): There is any read message to which no reply is made.
To read the message, see “MESSAGE DISPLAY (3-89)”.

CLOCK
The clock indicates the current time.

AFTERTREATMENT DEVICES REGENERATION PILOT LAMP

k CAUTION
• Exhaust gas temperature may increase higher than the previous models during the aftertreatment
devices regeneration. Stay away from the exhaust pipe outlet to prevent yourself from getting burnt.
Also, keep combustible materials away from the exhaust pipe outlet to prevent a fire.
• If there is a thatched roof, dead leaves, paper, or other combustible matter near the machine, see
“HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-126)”.

Aftertreatment devices regeneration display indicates the re-

generation state of the aftertreatment devices.
(A): Lights up during regeneration of the aftertreatment devi-
ces. It goes out when the regeneration is completed.
(B): Lights up when KDPF is set to regeneration disable.
REMARK
• The lighting cycle becomes shorter when the ambient tem-
perature is lower or working load is smaller.
• Even if the aftertreatment devices regeneration is disabled,
when the manual stationary regeneration is necessary,
KDPF soot accumulation caution lamp lights up. If KDPF
soot accumulation caution lamp lights up, cancel the re-
generation disable setting and perform manual stationary
regeneration.
For the procedures of cancellation of regeneration disable
setting, and setting of manual stationary regeneration, see
“HANDLE Komatsu Diesel Particulate Filter (KDPF)
(3-126)”.

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OPERATION EXPLANATION OF COMPONENTS

SECONDARY STEERING PILOT LAMP

When the secondary steering pilot lamp is lit in green while the
engine is running or the machine is operating, it is normal.
If it does not light up, there is a trouble in the secondary steer-
ing circuit.
Move the machine to a safe place, stop the engine, and per-
form the inspection and maintenance.

EMERGENCY HST PUMP DRIVE PILOT LAMP

The emergency HST pump drive pilot lamp lights up when the
emergency HST pump drive switch is turned on. At the same
time, the alarm buzzer sounds intermittently.

STEERING LOW OIL PRESSURE CAUTION LAMP

(if equipped)
Steering low oil pressure pilot pump lights up in red when the
steering pressure is low.
REMARK
While the engine is stopped, the steering pressure is low and
the steering low pressure pilot lamp lights up, but this does not
indicate any abnormality.

TRACTION LEVEL DISPLAY

The traction control operating state is displayed at the traction
level display.

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EXPLANATION OF COMPONENTS OPERATION

SHIFT LEVER POSITION DISPLAY

The shift lever position display shows the position of the direc-
tional lever or directional selector switch in enlarged letters.
The position of the selected speed range selector switch is also
displayed in enlarged letters.

WORK EQUIPMENT LOCK PILOT LAMP

The work equipment lock pilot lamp lights up when the work
equipment is locked.
This pops up on the screen when the work equipment is
switched from the unlock mode to the lock mode.

PARKING BRAKE PILOT LAMP

The parking brake pilot lamp lights up when the parking brake
is applied.
For detail, see “PARKING BRAKE SWITCH (3-96)”.

ECO GUIDANCE
ECO guidance is displayed during the operation that lowers the fuel efficiency, and support energy saving oper-
ation for reducing the fuel consumption.
The details of the guidance are as follows.
REMARK
Display/Non-display of ECO guidance can be switched.
For the method of switching the display, see “SWITCH DISPLAY/NON-DISPLAY OF ECO GUIDANCE (3-57)”.

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OPERATION EXPLANATION OF COMPONENTS

EXCESSIVE IDLING GUIDANCE

If the engine continues running idle for more than 5 minutes,
the excessive idling message is displayed on the monitor.
When waiting for work or taking short break, stop the engine to
reduce unnecessary fuel consumption.
When the accelerator pedal is depressed or the machine starts
traveling or the work equipment is operated, the excessive
idling message goes out.
For the auto idle stop function, see “AUTO IDLE STOP TIMER
SETTING (3-70)”.

GUIDANCE TO AVOID HYDRAULIC RELIEF

If the hydraulic equipment is relieved for more than 8 seconds
during operation, the hydraulic relief deterrence message is
displayed on the monitor.
The hydraulic equipment is relieved when an attempt is made
to lengthen each cylinder further over the maximum (for exam-
ple, to move bucket control lever to TILT while the bucket is
fully tilted) or reduce it further over the minimum.
Stop unnecessary relief.
The hydraulic relief deterrence message goes out automatically
after 10 seconds.

GUIDANCE OF ACCELERATOR PEDAL DEPRESSING LIMIT

If the accelerator pedal is depressed too much during opera-
tion, the notification of accelerator pedal depressing limit is dis-
played on the monitor.
Limit the accelerator operation in order to reduce the fuel con-
sumption.
The notification of accelerator pedal depressing limit goes out
automatically after 10 seconds.

TRACTION CONTROL RECOMMENDATION GUIDANCE

When “Fuel consumption improves when traction control is se-
lected.” is displayed on the monitor, using the traction control is
recommended to restrain the fuel consumption.
For using method of the traction control, see “TRACTION
CONTROL SWITCH (3-102)”.

DEF LOW LEVEL GUIDANCE

At 15 seconds after the starting switch is turned to ON position and the standard screen is displayed, if the oper-
able time estimated from current DEF level and the latest average DEF consumption is shorter than 8 hours,
DEF Level Low Error guidance is displayed.

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EXPLANATION OF COMPONENTS OPERATION

When the time until engine output power limitation starts is 1 to 8 hours
“Approx. * hours remaining to DEF refill caution.” is displayed.

When the time until engine output power limitation starts is less than 1 hour
“DEF refill caution will appear soon.” is displayed.

DEF Level Low Error guidance goes out in more than 15 seconds or when ENTER switch is pressed.
For the remaining amount of DEF, see “DEF LEVEL GAUGE (3-43)”.
REMARK
While monitor displays DEF level low error or maintenance warnings, DEF level low guidance is not displayed.

ENGINE STOP OPERATION DURING THE AFTERTREATMENT DEVICES REGEN-

ERATION GUIDANCE
Immediately after starting the aftertreatment devices regenera-
tion, the information about the engine stop operation during the
aftertreatment devices regeneration is displayed.
The information about the engine stop operation during the af-
tertreatment devices regeneration goes out when RETURN
switch is pressed.

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OPERATION EXPLANATION OF COMPONENTS

METER DISPLAY

(1) HST oil temperature gauge (6) Speedometer

(2) Engine coolant temperature gauge (7) DEF level gauge
(3) ECO gauge (8) Variable speed display
(4) Fuel gauge (9) R.H. meter
(5) Engine tachometer (10) L.H. meter

SPEEDOMETER
The speedometer indicates the travel speed of the machine.

ENGINE TACHOMETER
The engine tachometer indicates the engine speed.
If the engine speed is higher than the allowable range during
operation, the engine overrun caution lamp lights up in red. At
the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
Operate the machine with moderate engine speed and travel
speed.

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EXPLANATION OF COMPONENTS OPERATION

ENGINE COOLANT TEMPERATURE GAUGE

Engine coolant temperature gauge shows the engine coolant
temperature.
When the indicator is in the white or green range during opera-
tion, it is normal.
If the indicator is in the red range, the engine coolant tempera-
ture caution lamp lights up in red, and action level “L02” is dis-
played.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
The engine output is then limited automatically.
Place the machine in a safe place, set the directional lever and directional selector switch to NEUTRAL position
(N), and run the engine at a medium speed with no load until the engine coolant temperature caution lamp goes
out.

HST OIL TEMPERATURE GAUGE

The HST oil temperature gauge shows the HST oil tempera-
ture.
When the indicator is in the green range during operation, it is
normal.
If the indicator is in the red range, the HST oil temperature cau-
tion lamp lights up in red, and action level “L02” is displayed.
At the same time, the centralized warning lamp lights up and
alarm buzzer sounds intermittently.
Stop the machine in a safe place, set the directional lever and
directional selector switch to NEUTRAL position (N), and run
the engine at a medium speed with no load until the HST oil temperature caution lamp goes out.
If the HST oil temperature becomes less than 10 °C, the caution lamp is lit in white, and the travel speed accel-
eration is limited. Perform the warm-up operation to raise the HST oil temperature by referring to “METHOD
FOR RUNNING-IN THE NEW MACHINE (3-181)”.
REMARK
The setting to increase the engine low idle speed under the low ambient temperature is available. For details,
see “2-STAGE LOW IDLE SWITCH (3-100)”.

FUEL GAUGE
Fuel gauge shows the amount of fuel in the fuel tank.
If the indicator is in the red range, the fuel level caution lamp
lights up in red. The fuel level is below 33 ℓ. Check the fuel lev-
el, and add fuel.
REMARK
When the machine is traveling uphill, traveling downhill, per-
forming scraping-up work, the correct fuel level may not be dis-
played. However, this is not abnormal.

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OPERATION EXPLANATION OF COMPONENTS

VARIABLE SPEED DISPLAY

The variable speed display indicates the setting speed of travel
speed control dial.
(A): Speed range selection is 1st speed and maximum setting
speed is lower than 4 km/h.
(B): Speed range selection is 1st speed and maximum setting
speed is 4 km/h or higher.
(C) (D): These are displayed in gray and speed control function
is not actuated when selecting 2nd through 4th of the speed
range.
Setting speed is for reference since it varies depending on the
condition of road surface and load.
For the setting of travel speed control, see “TRAVEL SPEED
CONTROL DIAL (3-95)”.

ECO GAUGE
ECO gauge indicates the instantaneous fuel consumption (fuel
consumption rate at each moment).
The instantaneous fuel consumption varies depending on the
operation ways (accelerator operation, travel speed, speed
range, etc.) and the given load during travel (load weight,
slope, ground condition, etc.).
As the gauge is higher, the fuel consumption is higher. Reduce
the graduation of the gauge to a point where there is no ad-
verse effect on the operation, leading to energy saving opera-
tion to reduce the fuel consumption.
REMARK
Even if the gauge is in orange range (A), it is not a machine
trouble.
Target fuel consumption (B) displayed by ECO gauge can be
changed as necessary.

L.H. AND R.H. METER

The L.H. meter indicates either of the following which can be selected.
• Service meter
• Odometer
• Clock
For the method of selecting the display, see “SELECT L.H. METER DISPLAY (3-77)”.
The R.H. meter indicates either of the following which can be selected.
• Fuel consumption gauge
• Service meter
• Odometer
• Clock
For the method of selecting the display, see “SELECT R.H. METER DISPLAY (3-78)”.

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EXPLANATION OF COMPONENTS OPERATION

Service meter display

Indicates the integrated operating hours of the machine.
When the engine has run, the service meter advances even if
the machine is not being operated.
The service meter advances by 0.1 for 6 engine running mi-
nutes and by 1 for 1 engine running hour, regardless of the en-
gine speed.

Odometer display
Indicates the total distance that machine has traveled in kilo-
meters.

Clock display
Indicates the current time.
(A): 12-hour display
(B): 24-hour display
REMARK
If the battery is disconnected for a long period for storage etc.,
the time information may be lost.
For the method of setting and correcting the time and changing
the display of the clock, see “CLOCK ADJUSTMENT (3-80)”.

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OPERATION EXPLANATION OF COMPONENTS

Fuel consumption gauge display

Indicates the average fuel consumption of the machine.
(C): Average fuel consumption in a day
(D): Split fuel consumption (under measuring)
(E): Split fuel consumption (when measuring is stopped)
REMARK
Display on the fuel consumption gauge can be switched be-
tween the average fuel consumption per day (from 0:00 am of
the day to 0:00 am of the next day) and the average fuel con-
sumption during an selected period (split fuel consumption).
For details of the fuel consumption gauge and the method of
switching the display, see “SET DISPLAY OF FUEL CON-
SUMPTION GAUGE (3-54)”.

DEF LEVEL GAUGE

DEF level gauge indicates the remaining level of DEF.
If the indicator is in green range during operations, it is normal.
If the indicator comes close to (A) of red range during opera-
tion, check and add DEF.
(A) to (B): Red range
(A) to (C): Green range
When the indicator is in red range from (A) to (B), DEF level
caution lamp (1) lights up in red.
If DEF level further decreases after the lamp lights up in red,
the engine output and engine speed are limited. For detail, see
“HANDLE UREA SCR SYSTEM WARNING (3-135)”.
When remaining level of DEF cannot be detected, DEF level caution lamp (1) lights up in white.
REMARK
• Immediately after turning the starting switch to ON position and during the engine is running, DEF level cau-
tion lamp (1) lights up in white. However, this does not indicate abnormality.
• In cold weather, DEF level cannot be detected and DEF level caution lamp (1) lights up in white for approxi-
mately 1 hour. However, this does not indicate abnormality.
• Even if DEF level caution lamp (1) is not lit in white, it may take a long time for DEF level gauge to display
the correct position.
Note that the following cases are not abnormal:
• When DEF is added while the starting switch is kept at ON position.
• When the starting switch is turned to ON position immediately after adding DEF (within approximately
30 seconds).
Before adding DEF, turn the starting switch to OFF position. Wait for a while after adding, then turn the
starting switch to ON position.

MONITOR SWITCHES
This is used for the operation of the machine monitor or air conditioner.

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EXPLANATION OF COMPONENTS OPERATION

The function of each switch varies depending on the screen of the machine monitor.

(1) UP switch (5) RETURN switch

(2) Air conditioner switch and numeric keypad (6) DOWN switch
(3) Menu switch (7) Guidance icon
(4) ENTER switch
REMARK
• The switches available on each screen can be checked
with the guidance icon.
• This function is not available when you press a switch not
marked by the guidance icon or you press the guidance
icon itself.

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OPERATION EXPLANATION OF COMPONENTS

MENU SWITCH
When this switch is pressed on the standard screen, the follow-
ing user menu screen is displayed. The user menu screen is
not displayed during traveling.
For the user menu, see “USER MENU (3-46)”.
When normal: Displays the ECO guidance menu screen.
When KDPF soot accumulation caution lamp lights up: Dis-
plays the “Aftertreatment Devices Regeneration” menu screen.
When maintenance caution lamp lights up: Displays the “Main-
tenance” menu screen.
When fan reverse rotation pilot lamp lights up: Displays the
“Machine Setting and Information” menu screen.
When message pilot lamp lights up: Displays the Message display menu screen.
When the menu switch is pressed on the user menu screen, the menu screen changes.

ENTER SWITCH
Pressing ENTER switch on the user menu screen decides any
selection and changes, and proceeds to the next screen.
When ENTER switch is pressed on the standard screen with a
warning message displayed, the “Current Abnormality” screen
is displayed.
For the “Current Abnormality” screen, see “CURRENT AB-
NORMALITY LIST DISPLAY (3-17)”.

RETURN SWITCH
Pressing RETURN switch cancels a selection or changes, and
returns the screen to the previous screen or the standard
screen.

UP SWITCH
Pressing UP switch moves the cursor up by one item. When on
the first line, it moves to the last line.
On the value input screen, the value is increased by one.

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EXPLANATION OF COMPONENTS OPERATION

DOWN SWITCH
Pressing DOWN switch moves the cursor down by one item.
When on the last line, it moves to the first line.
On the value input screen, the value is decreased by one.

AIR CONDITIONER SWITCH AND NUMERIC KEYPAD

The air conditioner switch and the numeric keypad which are
used for the operation of the air conditioner consist of 10
switches.
For explanation of each switch, see “HANDLE AIR CONDI-
TIONER (3-213)”.
These switches can be used as a numeric keypad to enter a
numeric value such as a password.
Press a desired switch to enter a numeric value 0 to 9, which is
indicated at the lower right of each switch.

• For details of other switch functions, see the explanation for each screen in “USER MENU (3-46)”.
• The confirmation sound is heard when the switch is pressed, but a reaction is taken (the switch function is
operated) when the switch is released.

USER MENU
When menu switch (1) is pressed on the standard screen while
the machine is stopped, the user menu screen is displayed to
enable you to configure and confirm machine settings.

The user menu consists of the following kinds. The menu

screen can be changed by pressing the menu switch (1).
(A): “Energy Saving Guidance”
(B): “Machine Setting and Information”
(C): “Aftertreatment Devices Regeneration”
(D): “SCR Information”
(E): “Maintenance”
(F): “Monitor Setting”
(G): Message Display
These menus (A) to (G) are for setting and confirming the following items:

3-46
OPERATION EXPLANATION OF COMPONENTS

(A) “Energy Saving Guidance”

• Check of “Operation Records”
• Check of “ECO Guidance Records”
• Check and reset of “Average Fuel Consumption Record”
• “Configurations”

(B) “Machine Setting and Information”

• Setting for “Manual Fan Reverse Mode”
• Setting for “Automatic Fan Reverse Mode”
• “Traction Level Selection”
• Setting for “Traction Selection Hold”
• Setting for “Eco Traveling mode”
• Setting for “Reverse Travel Speed Range Limit”
• Setting for “Boom Raise Detent Setting”
• Setting for “PZ Auto Tilt-in Selection”
• Display and resetting of “Trip Meter”
• “Auto Idle Stop Timer Setting”
(C) “Aftertreatment Devices Regeneration”
• Setting for “Regeneration Disable”
• Operation of “Manual Stationary Regeneration”

(D) “SCR Information”

• Check of DEF level
• Information on DEF system

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EXPLANATION OF COMPONENTS OPERATION

(E) “Maintenance”
• Check and reset of various maintenance remaining times

(F) “Monitor Setting”

• “Rearview Monitor Setting”
• “Meter Display Selection”
• “Screen Adjustment”
• “Clock Adjustment”
• “Language Setting”
• “Operator ID”

(G) Message Display

• Check of message contents and reply to message

On the user menu screen, it is possible to perform the following

operations with the switches.
(2) UP switch
Moves to the item above.
When on the first item, it moves to the last item.
(3) DOWN switch
Moves to the item below.
When on the last item, moves to the first item.
(4) ENTER switch
Enters any selection or changes and proceeds to the next screen.
(5) RETURN switch
Cancels a selection or changes, and returns to the previous screen or the standard screen.
REMARK
• If no switch is operated for 30 seconds on the user menu screen, the screen automatically returns to the
previous screen or the standard screen.
• The user menu screen is displayed only while the machine is stopped completely.
• If the machine travels while the user menu screen is displayed, the screen automatically returns to the
standard screen.

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OPERATION EXPLANATION OF COMPONENTS

REMARK
The default tab when the standard screen is changed to the user menu screen varies with the machine condi-
tion.
If multiple conditions are established simultaneously, the following priority is given.
1. SCR event occurs → “SCR Information”
2. KDPF event occurs → “Aftertreatment Devices Regeneration”
3. Hydraulic fan is rotating in reverse → “Machine Setting and Information”
4. Maintenance caution occurs → “Maintenance”
5. Message is not read yet → Message display
6. Other than 1 to 5 → “Energy Saving Guidance”

ENERGY SAVING GUIDANCE

Each item of “Energy Saving Guidance” menu (A) is used for
displaying and setting the notification relevant to energy saving.
• “Operation Records”
• “Eco Guidance Records”
• “Average Fuel Consumption Record”
• “Configurations”

OPERATING RECORD
The “Operation Records” screen displays the following informa-
tion on a daily basis or during the split measurement period.
• “Working Hours (Engine On)”: The time during which the
engine is running
• “Average Fuel Consumption”: Average of the fuel con-
sumed while the engine is running
• “Actual Working Hours”: The time spent for traveling, oper-
ation of work equipment and operation of accelerator
• “Ave Fuel Consumption (Actual Working)”: Average of the
fuel consumed during actual work
• “Fuel Consumption”: The amount of fuel consumed
• “Idling Hours”: The time during which the machine is stop-
ped, and the work equipment and accelerator are not oper-
ated
• “KTCS Hours Ratio”:The ratio of time that traction control
is ON or S mode is selected to the time that engine is run-
ning.
Select “Operation Records” from the “Energy Saving Guidance”
menu screen, then press ENTER switch (1).
REMARK
For the definition and display change method of the “1 Day”
and “Split Time”, see “SET DISPLAY OF FUEL CONSUMP-
TION GAUGE (3-54)”.

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EXPLANATION OF COMPONENTS OPERATION

When “Average Fuel Consumption Display” is set to “1 Day”

“1 Day” is displayed on the place shown with arrow in the fig-
ure.

When “Average Fuel Consumption Display” is set to “Split Time”, and split time
is measured
(A) Display during measurement
(B) Date and time when measurement is started
To stop the split measurement, see the guidance icon and
press ENTER switch (1).

When display of “Average Fuel Consumption Display” is set to “Split Time”,

and split time measurement is stopped
(C) Display while measurement is stopped
(D) Dates and times when the measurement is started and
stopped
To start the split time measurement, see the guidance icon and
press ENTER switch (1).
When the measurement is started, the previous split time
measurement results (“Average Fuel Consumption Display”,
“Operation Records”, and “ECO Guidance Records”) are reset.

When the confirmation screen is displayed, press ENTER

switch (1) again to start the split measurement, or press RE-
TURN switch (2) to cancel the start.
NOTICE
The displayed value of fuel consumption may differ from
the actual value due to the operating conditions of the cus-
tomers (fuel, weather or work contents, etc.).

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OPERATION EXPLANATION OF COMPONENTS

ECO GUIDANCE RECORD

On “ECO Guidance Records” screen, the frequency of display
of the ECO guidance on a daily basis or during the split meas-
urement period and “Operational Advice” are displayed.

Select ECO Guidance Records from Energy Saving Guidance

menu screen, then press ENTER switch (1).
REMARK
• For the definition and display change method of “1 Day”
and “Split Time”, see “SET DISPLAY OF FUEL CON-
SUMPTION GAUGE (3-54)”.
• For the ECO guidance, see “ECO GUIDANCE (3-36)”.
• In the Operational Advice section, the advice to the ECO
guidance that appeared most frequently is displayed.
• The ECO guidance count increases when display condi-
tions are satisfied even if the ECO guidance is not dis-
played.
When “Average Fuel Consumption Display” is set to “1 Day”
“1 Day” is displayed on the place shown with arrow in the right
figure.

When “Average Fuel Consumption Display” is set to “Split Time”, and split time
is measured
(A) Display during measurement
(B) Date and time when measurement is started
To stop the split measurement, see the guidance icon and
press ENTER switch (1).

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EXPLANATION OF COMPONENTS OPERATION

When display of “Average Fuel Consumption Display” is set to “Split Time”,

and split time measurement is stopped
(C) Display while measurement is stopped
(D) Dates and times when the measurement is started and
stopped
To start the split time measurement, see the guidance icon and
press ENTER switch (1).
When the measurement is started, the previous split time
measurement results (“Average Fuel Consumption Display”,
“Operation Records”, and “ECO Guidance Records”) are reset.

When the confirmation screen is displayed, press ENTER

switch (1) again to start the split measurement, or press RE-
TURN switch (2) to cancel the start.

FUEL CONSUMPTION RECORD

The “Average Fuel Consumption Record” screen alternately
displays the following graphs.
• Average fuel consumption for the “Last 12 hours”
• Average fuel consumption for the “Last 7 days”.
Select “Average Fuel Consumption Record” from the “Energy
Saving Guidance” menu screen, then press ENTER switch (1).
To change a graph, see the guidance icon and press menu
switch (2).

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OPERATION EXPLANATION OF COMPONENTS

• When display of the “Last 12 hours” is selected

• When display of the “Last 7 days” is selected

REMARK
The graph of the “Last 12 hours” is updated every hour of the service meter reading.
The graph of the “Last 7 days” is updated every day.
To clear a graph, see the guidance icon and press ENTER
switch (1).
When the confirmation screen is displayed, press ENTER
switch (1) again to clear or press RETURN switch (3) to cancel
clearing.
REMARK
If clearing is performed while the graph of the “Last 12 hours” is
displayed, only the graph of the “Last 12 hours” is cleared.
If clearing is performed while the graph of the “Last 7 days” is
displayed, both graphs of the “Last 12 hours” and “Last 7 days”
are cleared.

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EXPLANATION OF COMPONENTS OPERATION

DISPLAY SETTING
On the “Configurations” menu, it is possible to perform follow-
ing settings.
• Setting “Average Fuel Consumption Display”
• Switching ON/OFF of “ECO Gauge Display”
• Setting “ECO Gauge Display Fuel Target Value”
• Switching ON/OFF of ECO guidance
• Switching ON/OFF of “ECO Guidance Display at Key OFF”
Select “Configurations” from “Energy Saving Guidance” menu
screen, then press ENTER switch (1).

SET DISPLAY OF FUEL CONSUMPTION GAUGE

The display of the fuel consumption gauge can be set to the
value on daily basis or during split measurement period.

1. Select “Average Fuel Consumption Display” from “Configu-

rations” menu, then press ENTER switch (1).

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OPERATION EXPLANATION OF COMPONENTS

2. Select “1 Day” or “Split Time”, then press ENTER switch

(1).
The default is “1 Day”.
To cancel, press RETURN switch (2).
“1 Day”
Displays the average fuel consumption in 1 day from 0:00 a.m.
of the day to 0:00 a.m. of the next day.
Reset at 0.00 a.m. of the next day.
“Split Time”
Displays the average fuel consumption during the split measurement period (after the measurement is started
until it is finished).
Select “Split Time” to start the split measurement automatically.
REMARK
Setting of “1 Day” or “Split Time” is also applied to the display of the “Operation Records” and “ECO Guidance
Records”.

SWITCH DISPLAY/NON-DISPLAY OF ECO GAUGE

Display/non-display of ECO gauge can be switched.

1. Select “ECO Gauge Display” from the “Configurations”

menu, then press ENTER switch (1).

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EXPLANATION OF COMPONENTS OPERATION

2. Select “ON” or “OFF”, then press ENTER switch (1).

“ON”
Displays the ECO gauge.
“OFF”
Does not display the ECO gauge.
To cancel, press RETURN switch (2).
The default is “ON”.
REMARK
If the “ECO Gauge Display” is set to “OFF”, the items of “ECO
Gauge Display Fuel Target Value” is not displayed.

SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE

ECO Gauge Target Value (A) (the upper limit value of the green
range) can be changed.

1. Select “ECO Gauge Display Fuel Target Value” from “Con-

figurations” menu, then press ENTER switch (1).

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OPERATION EXPLANATION OF COMPONENTS

2. Use UP switch (2) or DOWN switch (3) to set the value,

and press ENTER switch (1).
(2) UP switch
Increases the target fuel consumption value by 1 ℓ/h.
(3) DOWN switch
Decreases the target fuel consumption value by 1 ℓ/h.
To cancel, press RETURN switch (4).
The default is 27 ℓ/h.
REMARK
If the target fuel value is increased, the fuel consumption indi-
cated when the ECO gauge is at the maximum is also in-
creased in proportion.
If the target fuel value is decreased, the fuel consumption indi-
cated when the ECO gauge is at the maximum is also de-
creased in proportion.

SWITCH DISPLAY/NON-DISPLAY OF ECO GUIDANCE

Display/non-display of ECO guidance displayed on the stand-
ard screen can be switched.

1. Select “ECO Guidance Display ” from “Configurations”

menu, then press ENTER switch (1).

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EXPLANATION OF COMPONENTS OPERATION

2. Select “ON” or “OFF”, then press ENTER switch (1).

“ON”
Displays the ECO guidance.
“OFF”
Does not display the ECO guidance.
To cancel, press RETURN switch (2).
The default is “ON”.
REMARK
If “ECO Guidance Display” is turned “OFF”, displays of “ECO
Guidance Display at Key OFF” and “ECO Guidance Records”
are not displayed. “ECO Guidance Records”, however, is not
reset.

SWITCH DISPLAY/NON-DISPLAY OF GUIDANCE WHEN KEY IS OFF

Display/non-display of the “Operational Advice” indicated on
the end screen when the key is turned to OFF position can be
switched.

1. Select “ECO Guidance Display at Key OFF” from “Configu-

rations” menu, then press ENTER switch (1).

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OPERATION EXPLANATION OF COMPONENTS

2. Select “ON” or “OFF”, then press ENTER switch (1).

“ON”
Displays the operational advice on the end screen.
“OFF”
Does not display the operational advice on the end screen.
To cancel, press RETURN switch (2).
The default is “ON”.
REMARK
In the “Operational Advice” section indicated on the end
screen, the advice to the ECO guidance that was displayed
most frequently after the starting switch is turned to ON posi-
tion is indicated. Accordingly, the operational advice indicated
on the end screen may be different from the “Operational Ad-
vice” indicated on “ECO GUIDANCE RECORD (3-51)”.

MACHINE SETTING AND INFORMATION

In each item of “Machine Setting and Information” menu (B),
setting and information of the machine are checked or
changed.

RADIATOR FAN MANUAL REVERSE MODE

k CAUTION
When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth, etc.
will not be wound in the fan.
Dust may be blown up. Check that there is no person around the machine while the fan is rotating in the
reverse direction.

In the manual fan reverse mode, the fan may be rotated in reverse to blow off mud or dirt sticking to the radiator.
1. Set the engine speed to low idle.

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EXPLANATION OF COMPONENTS OPERATION

2. Select “Manual Fan Reverse Mode” on the “Machine Set-

ting and Information”, and press ENTER switch (1).
REMARK
The fan rotation switches from the normal direction to the
reverse direction only when all of the following conditions
are met.
• The engine coolant temperature is less than 102 °C.
• The boost temperature is less than 119 °C.
• The HST oil temperature is less than 100 °C.
• It has been 20 seconds or more since the engine was
started.

3. Press ENTER switch (1) to rotate the fan in the reverse di-
rection, or press RETURN switch (2) to cancel.

If the fan reverse operation is performed without satisfying

the condition for reversing the fan, the screen shown in the
figure is displayed, and the fan rotation direction cannot be
switched.
In this case, press RETURN switch (2), and then repeat
the procedure from the first.

4. Fan reverse rotation pilot lamp (3) flashes, then lights up.

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OPERATION EXPLANATION OF COMPONENTS

If the condition for reversing the fan is not satisfied,

changeover condition waiting pilot lamp (4) lights up in red.
5. Set the engine speed to high idle and perform thecleaning.
6. After finishing the cleaning, set the engine speed to low
idle.

7. If the menu switch is pressed on the standard screen, the

screen shown in the figure is displayed.
Press ENTER switch to return the fan to the normal rota-
tion mode.
Fan reverse rotation pilot lamp (3) flashes and then goes
out.
REMARK
If one of the following conditions is satisfied, the fan rotation re-
turns from reverse direction to normal direction.
• Perform the manual fan reverse operation again while the
fan is rotating in reverse.
• 10 minutes elapses after the fan rotation direction is re-
versed.
• Stop the engine.
• The coolant temperature, boost temperature, or HST oil
temperature overheat (the caution lamp of the oil tempera-
ture gauge or coolant temperature gauge on the machine
monitor lights up in red, then action level “L02” is dis-
played) while the fan is rotating in reverse.

RADIATOR FAN AUTOMATIC REVERSE MODE

k CAUTION
When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth, etc.
will not be wound in the fan.
Dust may be blown up. Check that there is no person around the machine while the fan is rotating in the
reverse direction.

In the automatic fan reverse mode, you can configure the setting for automatically rotating the fan in the reverse
direction to blow off mud and dirt sticking to the radiator.

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EXPLANATION OF COMPONENTS OPERATION

1. Select “Automatic Fan Reverse Mode” from “Machine Set-

ting and Information” menu, and press ENTER switch (1).

2. Select the duration and cycle of the automatic fan reverse,

and press ENTER switch (1).
The following 4 items can be selected.
“OFF”
The fan does not rotate in reverse direction automatically.
“Mode A”
The fan rotates in the reverse direction for 1 minute once
for every 2 hours.
“Mode B”
The fan rotates in the reverse direction for 1 minute once for every 1 hours.
“Mode C”
The fan rotates in the reverse direction for 4 minute once for every 0.5 hours.
The default is “Mode A”.
When you want other than above settings for the duration and cycle of the automatic fan reverse rotation,
consult your Komatsu distributor.
REMARK
The fan rotation switches from the normal direction to the reverse direction only when all of the following
conditions are met.
• Other than “OFF” is set in “Automatic Fan Reverse Mode”.
• The set changeover time for “Automatic Fan Reverse Mode” has elapsed.
• The engine coolant temperature is less than 102 °C.
• The boost temperature is less than 119 °C.
• The HST oil temperature is less than 100 °C.
• It has been 20 seconds or more since the engine was started.

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OPERATION EXPLANATION OF COMPONENTS

3. When the set changeover time elapses, fan reverse rota-

tion pilot lamp (2) flashes and lights up.

If the condition for reversing the fan is not satisfied,

changeover condition waiting pilot lamp (3) lights up in red.

4. The fan returns from the reverse rotation to the normal

when the set duration for the reverse rotation elapses.
Fan reverse rotation pilot lamp (2) flashes and then goes
out.
REMARK
If one of the following conditions is satisfied, the fan rota-
tion returns from reverse direction to normal direction.
• Turn off the automatic fan reverse mode.
• The set duration time for the automatic fan reverse
mode has elapsed.
• Stop the engine.
• The coolant temperature, boost temperature, or HST
oil temperature overheat (the caution lamp of the oil
temperature gauge or coolant temperature gauge on
the machine monitor lights up in red, then action level
“L02” is displayed) while the fan is rotating in reverse.

TRACTION LEVEL SELECTION

A suitable traction level in accordance with the operating condition can be selected according to the following
procedure.

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EXPLANATION OF COMPONENTS OPERATION

1. Select “Traction Level Selection” on “Machine Setting and

Information” menu, then press ENTER switch (1).

2. Select the traction level in accordance with the operating

condition, then press ENTER switch (1).
“Auto”
• Controller judges the operating condition, and set the
maximum rim pull automatically.
• Optimum control of the HST pump and HST motor ac-
cording to the work load is performed and it can re-
strain the fuel consumption.
• When the Eco Traveling mode is set to “ON”, the fuel
consumption during traveling at 3rd or 4th can be re-
duced.
“Level 1” to “Level 5”
Most suitable setting can be selected in accordance with the specific gravity of handled material, operating
condition, and application.
Initially, “Auto” is selected.

TRACTION LEVEL SELECTION HOLD

You can decide whether the selected traction mode at the engine stop should be held or not according to the
following procedure.

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OPERATION EXPLANATION OF COMPONENTS

1. Select “Traction Selection Hold” on “Machine Setting and

Information” menu, and press ENTER switch (1).

2. Select “ON” or “OFF”, then press ENTER switch (1).

“ON”
The selected traction mode at key OFF is held.
“OFF”
The traction mode at key OFF is returned to “Auto”.
“OFF” is set as default. Accordingly, “Auto”, which is effec-
tive to reduce the fuel consumption and tire wear, is select-
ed at key OFF.

ECO TRAVELING MODE

The fuel consumption during traveling at 3rd or 4th can be reduced while the traction level is set to “Auto” by
setting “Eco Traveling mode” to “ON” position.

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EXPLANATION OF COMPONENTS OPERATION

1. Select “Eco Traveling mode” on “Machine Setting and In-

formation” menu, then press ENTER switch (1).

2. Select “ON” or “OFF”, then press ENTER switch (1).

“OFF”
Returns to the normal mode.
“ON”
Reduces the fuel consumption during traveling at 3rd or
4th while the traction level is set to “Auto”.
The default is “ON”.

REVERSE TRAVEL SPEED RANGE LIMITATION

Even when the speed range selector switch is at 3rd or 4th, the speed range in reverse travel can be limited to
2nd or below.

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OPERATION EXPLANATION OF COMPONENTS

1. Select “Reverse Travel Speed Range Limit” on “Machine

Setting and Information” menu, and press ENTER switch
(1).

2. Select “ON” or “OFF”, then press ENTER switch (1).

“OFF”
OFF: Reverse speed range is not limited.
“ON”
Even when the travel speed range is set in 3rd or 4th, the
reverse travel speed range is limited to 2nd or below.
The default is “OFF”.

BOOM RAISE DETENT SETTING

With the boom RAISE detent function, the multifunction mono-lever can be stopped in the position where it is
pulled further from “RAISE” position.

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EXPLANATION OF COMPONENTS OPERATION

1. Select “Boom Raise Detent Setting” on “Machine Setting

and Information” menu, and press ENTER switch (1).

2. Select “ON” or “OFF”, then press ENTER switch (1).

“ON”
The boom RAISE detent is enabled.
“OFF”
The boom RAISE detent is disabled.
The default is “ON”.
REMARK
When the boom RAISE detent is disabled, the remote position-
er function is disabled as well.
For details, see “REMOTE POSITIONER (3-201)”.

PZ AUTO TILT-IN SELECT

With PZ auto tilt-in function, the spillage of the loaded material can be prevented by tilting the bucket automati-
cally while the boom is raised.

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OPERATION EXPLANATION OF COMPONENTS

1. Select “PZ Auto Tilt-in Selection” on “Machine Setting and

Information” menu, and press ENTER switch (1).

2. Select the setting of PZ Auto Tilt-in and press ENTER

switch (1).
“OFF”
PZ auto tilt-in function is disabled.
“Light”
Sets the compensation angle of auto tilt-in to smaller val-
ue.
“Normal”
Sets the compensation angle of auto tilt-in to standard val-
ue.
“Heavy”
Sets the compensation angle of auto tilt-in to larger value.
Initially, “Normal” is selected.

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EXPLANATION OF COMPONENTS OPERATION

TRIP METER
The overall travel distance after the previous resetting can be
checked by using the “Trip Meter”.
You can reset the travel distance according to the following pro-
cedure.
1. Select “Trip Meter” on “Machine Setting and Information”
menu, then press ENTER switch (1).

2. Press ENTER switch (1) to reset or press RETURN switch

(2) to cancel resetting.

AUTO IDLE STOP TIMER SETTING

It is used to stop the engine automatically when the idle state continued for a predetermined time.
The auto idle stop works only when all of the following conditions are met.
• The engine is running normally.
• The parking brake works properly.
• The accelerator pedal is not depressed.
• The directional lever and directional selector switch are in NEUTRAL position (N).
• The machine is stopped.
• The engine coolant is not overheated.
• The aftertreatment devices are not in regeneration.
• The parts of DEF system are not in thawing control.

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OPERATION EXPLANATION OF COMPONENTS

1. Select “Auto Idle Stop Timer Setting” on “Machine Setting

and Information” menu, and press ENTER switch (1).

2. Select the operating time of the auto idle stop, and press ENTER switch (1).
The operating time can be selected from 3 minutes to 60
minutes.
REMARK
Selecting “OFF” disables operation of the auto idle stop.

3. If the idle state is continued up to 30 seconds before the

current auto idle stop timer setting, the countdown screen
is displayed on the standard screen.
If you increase the engine speed or set the directional lev-
er or directional selector switch to any position other than
NEUTRAL (N) at this point, the countdown is stopped and
the screen returns to the standard screen.

4. If the idle state is further continued and the countdown

reaches 0 seconds, the engine stops.
The work equipment is locked as well after the engine is
stopped.
Turn the unnecessary switches to OFF position to prevent
the battery to run out.
REMARK
When the auto idle stop starts while the parking brake is off, re-
lease the parking brake by turning it on once and turning it off
again.
When restarting the engine, turn the starting switch key as usual.

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EXPLANATION OF COMPONENTS OPERATION

AFTERTREATMENT DEVICES REGENERATION

Each item of “Aftertreatment Devices Regeneration” menu (C)
is for settings and operations of the aftertreatment devices re-
generation.
For details of the aftertreatment devices regeneration, see
“HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-126)”.
The operation methods and the contents of the display of
KDPF regeneration and urea SCR regeneration are common.

SCR INFORMATION
Each item in “SCR Information” menu (D) is for displaying infor-
mation related to SCR and DEF.
For details of “SCR Information”, see “HANDLE UREA SCR
SYSTEM WARNING (3-135)”.

MAINTENANCE SCREEN SETTING

Each item on “Maintenance” menu screen (E) is used for dis-
playing and setting the notification relevant to maintenance.
On the “Maintenance” menu screen, the following maintenance
items, their replacement intervals, and their remaining times to
the next replacement are displayed.

Interval ( h)
Maintenance item
(Default)
Air Cleaner Cleaning or Change -
Coolant Change -
Engine Oil Change 500
Engine Oil Filter Change 500
Fuel Prefilter Change 500
Fuel Main Filter Change 1000
Transfer Oil Change 1000
HST Oil Filter Change 1000
DEF Tank Breather Change 2000
Hydraulic Oil Filter Change 2000
Hyd Oil Tank Breather Change 2000
Hydraulic Oil Change 2000

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OPERATION EXPLANATION OF COMPONENTS

Interval ( h)
Maintenance item
(Default)
Axle Oil Change 2000
KCCV Filter Change 2000
DEF Filter Change 2000
KDPF Filter Cleaning 4500
DEF Tank Washing 4500

When the time remaining to the next “Maintenance” for any

item is less than the maintenance notice time (initial setting: 30
hours), the remaining time display (1) is highlighted in yellow.
When the time remaining to the maintenance becomes 0
hours, the Remain (1) is highlighted in red. The time after the
replacement interval is indicated with the negative symbol.
If any item is displayed in red, perform the maintenance for it
immediately.
REMARK
The replacement intervals in “Air Cleaner Cleaning or Change”
and “Coolant Change” are not set initially.
If you want to change the setting for the maintenance interval
and the maintenance notice time, consult your Komatsu distrib-
utor.
When the maintenance time caution lamp (2) is lit on the stand-
ard screen, press the menu switch, and the screen automati-
cally displays the “Maintenance” menu screen (E).

METHOD FOR RESETING REMAINING TIME FOR MAINTENANCE

After performing maintenance, reset the remaining time for maintenance according to the following procedure.

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EXPLANATION OF COMPONENTS OPERATION

1. On “Maintenance” menu screen, select an item to reset the

remaining time, then keep pressing ENTER switch (1) for
more than 1.5 seconds.
REMARK
If ENTER switch (1) is not pressed for enough time, the
switch operating sound can be heard, but the screen does
not switch to the screen for resetting the remaining time for
maintenance.

When a password for restriction of use has been set, the

password input screen is displayed.
Input the password for restriction of use by using the nu-
meric keypad, then press ENTER switch (1).
REMARK
For the setting, changing, or canceling the password, ask
your Komatsu distributor.

2. The screen changes to Maintenance Due Time Reset

screen.
When ENTER switch (1) is pressed, the following reconfir-
mation screen is displayed.
To cancel, press RETURN switch (2).

3. On the reconfirmation screen shown in the figure, when

ENTER switch (1) is pressed again, the remaining time is
reset and the screen returns to the “Maintenance” menu
screen.
To cancel, press RETURN switch (2).
REMARK
If the remaining time and the replacement interval are the
same, the remaining time cannot be reset.

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OPERATION EXPLANATION OF COMPONENTS

MONITOR SETTINGS
Each item of “Monitor Setting” menu (F) is to make settings for
the machine monitor.

REAR VIEW MONITOR SETTING

This is used to set the rearview monitor.
Select “Rearview Monitor Setting” on the “Monitor Setting”
menu screen, and press ENTER switch (1).

Reference line display

The is used to change ON/OFF of the reference line on the rearview monitor.
1. Select “Guide Line Display Mode” from the “Rearview
Monitor Setting” menu, and press ENTER switch (1).

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EXPLANATION OF COMPONENTS OPERATION

2. Select “ON” or “OFF”, then press ENTER switch (1).

“ON”
Displays the reference line.
“OFF”
Hides the reference line.
REMARK
For the rearview monitor and the reference line, see “HANDLE
REAR VIEW MONITOR (3-125)” and “METHOD FOR AD-
JUSTING REAR VIEW CAMERA ANGLE (3-169)”.
This setting is held even if the starting switch is turned to OFF position.
The default is “ON”.

REVERSE-INTERLOCK ENABLED MODE

In this mode, display method of rear view monitor can be changed by switching ON/OFF.
1. Select “Reverse-interlock Selection mode” on the “Rear-
view Monitor Setting” menu, then press ENTER switch (1).

2. Select “ON” or “OFF”, then press ENTER switch (1).

“ON”
Displays images on the rear view monitor only when trav-
eling in reverse.
“OFF”
Always displays images on the rear view monitor.
REMARK
This setting is held even if the starting switch is turned to OFF
position.
The default is “OFF”.

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METER DISPLAY SELECTION

This is used for the selection of the items to be displayed on
L.H. meter display (A) or R.H. meter display (B).

Select “Meter Display Selection” on the “Monitor Setting” menu

screen, then press ENTER switch (1).

SELECT L.H. METER DISPLAY

This is used for the selection of the items to be displayed on the L.H. meter display.

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EXPLANATION OF COMPONENTS OPERATION

1. Select “LH Meter Display Selection” on the “Meter Display

Selection” menu, then press ENTER switch (1).

2. Select the items to be displayed, then press ENTER switch

(1).
The following 3 items can be selected.
• “SMR: Service Meter”
• “ODO: Odometer”
• “CLK: Clock”
REMARK
For details of each item, see “L.H. AND R.H. METER (3-41)”.
The default of L.H. meter is “SMR: Service Meter”.

SELECT R.H. METER DISPLAY

This is used for the selection of the items to be indicated on the R.H. meter display.

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OPERATION EXPLANATION OF COMPONENTS

1. Select “RH Meter Display Selection” on the “Meter Display

Selection” menu, then press ENTER switch (1).

2. Select the items to be displayed, then press ENTER switch

(1).
The following 4 items can be selected.
• “FUEL: Average Fuel Consumption”
• “SMR : Service Meter”
• “ODO: Odometer”
• “CLK: Clock”
REMARK
For details of each item, see “L.H. AND R.H. METER (3-41)”.
The default of R.H. meter is “FUEL: Average Fuel Consump-
tion”

SCREEN ADJUSTMENT
This function is used for the adjustment of brightness of the machine monitor.
1. Select “Screen Adjustment” on the “Monitor Setting”
screen, then press ENTER switch (5).

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EXPLANATION OF COMPONENTS OPERATION

2. Adjust the brightness by using the switch panel.

The brightness can be adjusted individually in the day and
night modes.
(1) Menu switch
Brightness is set to default.
(2) UP switch
Brightness increases. (Moves the indicator to the right by
one division.)
(3) DOWN switch
Brightness decreases. (Moves the indicator to the left by
one division.)
(4) RETURN switch
Cancels the change and returns to “Monitor Setting” menu.
(5) ENTER switch
Accepts the change and then returns to “Monitor Setting”
menu.
REMARK
When the screen is adjusted while the lamp switch is turned
off, the brightness in the day mode can be adjusted.
Turn on the lamp switch, then adjust the screen when the moni-
tor brightness selector switch is set to the night mode, the
brightness in the night mode can be adjusted.
The brightness of night illumination for the switch panel and op-
eration switches are adjusted synchronously with the bright-
ness of the machine monitor.

CLOCK ADJUSTMENT
On the clock adjustment menu, you can change the setting of
the clock displayed on the standard screen.
The following items can be changed.
“GPS Synchronization”
“Calendar”
“Time”
“12hour or 24hour Mode”
“Daylight Saving Time”
Select “Clock Adjustment” on the “Monitor Setting” menu
screen, then press ENTER switch (1).
REMARK
After a long-term storage of the machine, Calendar and Time
are reset, so you must readjust them.
When the “GPS Synchronization” is set to “ON”, the above are
automatically readjusted.

GPS SYNCHRONIZATION
On the machines equipped with KOMTRAX, you can configure automatic setting of the machine monitor's date
and time in accordance with the GPS's clock.

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OPERATION EXPLANATION OF COMPONENTS

1. Select “GPS Synchronization” from the “Clock Adjustment”

menu, then press ENTER switch (1).

2. Select “ON” or “OFF”, then press ENTER switch (1).

“ON”
Sets the date and time automatically.
“OFF”
Does not set the date and time automatically. (Can be set
manually.)
REMARK
This setting is held even if the starting switch is turned to OFF
position.
The default is “OFF”.
When the machine is in the environment where the radio
waves from GPS cannot be received, the automatic setting
function might be disable.
Turning the “GPS Synchronization” “ON” disables selecting the
“Calendar” and “Time”.

CALENDAR SETTING
Adjust the date of the machine monitor.

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EXPLANATION OF COMPONENTS OPERATION

1. Select “Calendar” from the “Clock Adjustment” menu, then

press ENTER switch (4).
REMARK
As long as “ON” is selected for the “GPS Synchronization”,
“Calendar” is not selectable.

2. The “Calendar” screen is displayed.

When year display (A) is highlighted in yellow, operate the
switches as follows to change year display.
When it is not necessary to change the year setting, press
ENTER switch (4).
(1) UP switch
Advances calendar one year.
(2) DOWN switch
Puts calendar back one year.
(3) RETURN switch
Cancels the change and returns the screen to “Clock Adjustment” menu.
(4) ENTER switch
Proceeds to setting for month.
3. When month display (B) is highlighted in yellow, operate
the switches as follows to change month display.
When it is not necessary to change the month setting,
press ENTER switch (4).
(1) UP switch
Advances calendar one month.
(2) DOWN switch
Puts calendar back one month.
(3) RETURN switch
Cancels change and returns to setting for year.
(4) ENTER switch
Proceeds to setting for day.

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OPERATION EXPLANATION OF COMPONENTS

4. When day display (C) is highlighted in yellow, operate the

switches as follows to change day display.
When it is not necessary to change the day setting, press
ENTER switch (4).
(1) UP switch
Advances calendar one day.
(2) DOWN switch
Puts calendar back one day.
(3) RETURN switch
Cancels change and returns to setting for month.
(4) ENTER switch
Accepts change and returns the screen to the “Clock Adjustment” screen.

TIME SETTING
Adjust the time of the machine monitor clock.
1. Select “Time” from the “Clock Adjustment” menu, and
press ENTER switch (4).
REMARK
If “ON” is selected for the setting of “GPS Synchroniza-
tion”, you cannot select the “Time”.

2. The “Time” screen is displayed.

When time display (D) is highlighted in yellow, operate the
switches as follows to change time display.
When it is not necessary to change the time setting, press
ENTER switch (4).
(1) UP switch
Advances time one hour.
(2) DOWN switch
Puts time back one hour.
(3) RETURN switch
Cancels the change and returns the screen to “Clock Adjustment” menu.
(4) ENTER switch
Proceeds to setting for minute.

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EXPLANATION OF COMPONENTS OPERATION

3. When minute display (E) is highlighted in yellow, operate

the switches as follows to change minute display.
When it is not necessary to change the minute setting,
press ENTER switch (4).
(1) UP switch
Advances time one minute.
(2) DOWN switch
Puts time back one minute.
(3) RETURN switch
Cancels change and returns to the time setting screen.
(4) ENTER switch
Accepts change and returns the screen to the “Clock Adjustment” screen.

12-HOUR AND 24-HOUR DISPLAY MODE

Choose either a 12-hour display (AM, PM) or a 24-hour display.
1. Select “12hour or 24hour Mode” from the “Clock Adjust-
ment” menu, then press ENTER switch (1).

2. Select “12hour” or “24hour”, then press ENTER switch (1).

“12hour”
Select 12-hour display (AM, PM).
“24hour”
Select 24-hour display.
REMARK
This setting is held even if the starting switch is turned to OFF
position.
The default is “24hour”.

DAYLIGHT SAVING TIME (SUMMER TIME)

Set the clock display based on the Daylight Saving Time.

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OPERATION EXPLANATION OF COMPONENTS

1. Select “Daylight Saving Time” from the “Clock Adjustment”

menu, then press ENTER switch (1).

2. Select “ON” or “OFF”, then press ENTER switch (1).

“ON”
Displays the time 1 hour forward.
“OFF”
Returns the time to the original.
REMARK
Daylight saving time or summer time means moving the clock
forward an hour to take advantage of the fact that the sun rises
early in summer in our daily life.
This setting is held even if the starting switch is turned to OFF
position.
The default is “OFF”.

LANGUAGE SETTINGS
The language displayed on the machine monitor can be selected.
The languages that can be selected are as follows.
English, Japanese, French, Spanish, Portuguese, Italian, German, Swedish, Dutch, Danish, Norwegian, Fin-
nish, Icelandic, Czech, Hungarian, Polish, Slovak, Slovene, Romanian, Croatian, Estonian, Latvian, Lithuanian,
Bulgarian, Greek, Serbian, Turkish

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EXPLANATION OF COMPONENTS OPERATION

1. Select “Language Setting” on the “Monitor Setting” menu

screen, then press ENTER switch (1).

2. Select the language to be displayed, then press ENTER

switch (1).
REMARK
This setting is held even if the starting switch is turned to OFF
position.

OPERATOR ID
You can check and change the “Operator ID” which is under identification on the “Operator ID” menu.
The “Operator ID” menu is not displayed when the operator identification function is disabled.
REMARK
Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi-
fication function.

WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP

When the starting switch is ON and ID is inputted, the identified
ID is displayed in the column of “Operator ID” on the “Monitor
Setting” menu screen.

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OPERATION EXPLANATION OF COMPONENTS

When the starting switch is ON and “SKIP” is selected, “****” is

displayed in the column of “Operator ID” on the “Monitor Set-
ting” menu screen.

1. Select “Operator ID” on the “Monitor Setting” menu screen,

then ENTER switch (1) for 1 second.

2. The “Operator ID Change” screen is displayed.

• Input the already registered ID on the “Operator ID

Change” screen and press ENTER switch (1). Then,
the identified ID can be changed.
A message is displayed below and the screen returns
to the “Monitor Setting” menu screen.
On the “Monitor Setting” menu screen, the inputted ID
is displayed in the column of “Operator ID”.

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EXPLANATION OF COMPONENTS OPERATION

• When you press menu switch (2) on the “Operator ID

Change” screen, a message is displayed below and
the screen returns to the “Monitor Setting” menu
screen.
On the “Monitor Setting” menu screen, as the same
way when the starting switch is ON and “SKIP” is se-
lected, “****” is displayed in the column of “Operator
ID”.
In this case, the operator ID is not identified.

• When you press ENTER switch (1) after inputting the

ID which is not registered to the “Operator ID Change”
screen, a message is displayed below and the screen
returns to the “Monitor Setting” menu screen.
In this case, the identified ID is not changed.
• On the “Operator ID” screen, if no switch is operated
for more than 30 seconds, the screen automatically
changes to the “Monitor Setting” menu screen.
In this case, the identified ID is not changed.

WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP

When the operator identification function is available without
SKIP, the identified ID number is not displayed in the “Operator
ID” column of “Monitor Setting” screen.

1. Select “Operator ID” on the “Monitor Setting” menu screen,

then ENTER switch (1) for 1 second.

2. The “Operator ID Change” screen is displayed.

3-88
OPERATION EXPLANATION OF COMPONENTS

• Input the already registered ID on the “Operator ID

Change” screen and press ENTER switch (1). Then,
the identified ID can be changed.
A message is displayed below and the screen returns
to the “Monitor Setting” menu screen.

• When you press ENTER switch (1) after inputting the

ID which is not registered to the “Operator ID Change”
screen, a message is displayed below and the screen
returns to the “Monitor Setting” menu screen.
In this case, the identified ID is not changed.
• On the “Operator ID” screen, if no switch is operated
for more than 30 seconds, the screen automatically
changes to the “Monitor Setting” menu screen.
In this case, the identified ID is not changed.

MESSAGE DISPLAY
On machines equipped with KOMTRAX, you can see the mes-
sages from your Komatsu distributor on this User Message
menu (G).

When there is any message, message display (1) of the stand-

ard screen lights up.

(A): There is unread message.

(B): There is any read message to which no reply is made.
Reply to the message in accordance with the replying method
mentioned later.

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EXPLANATION OF COMPONENTS OPERATION

REMARK
• While message display (1) is lit on the standard screen,
when menu switch (2) is pressed, User Message menu
screen (G) is displayed automatically.
• When the starting switch is turned OFF while there is any
unread message, the message is displayed on the end
screen, and when the monitor is started next time, the
message changes to a read message.
• The message is deleted when it becomes out of date or
when a new message reaches.

CHECK MESSAGE
Select message display menu screen (G), and you can read
the arrived message.
(A) Subject of message
When no message has been received, “No message.” is dis-
played.
(B) Serial No. of message
(C) Validity
(D) Text
(E) Reply field
In case of a message requesting for reply, the “Numeric Input: [ ]” is displayed. Make any reply to the message.

REPLY TO MESSAGE
1. When replying to a message, input the selected item num-
ber shown in the text of the message by using the switch
panel.
• Each switch of the switch panel corresponds to the
number shown on the lower right of the switch.
• The input number is displayed in “Numeric Input: [ ]”of
the reply field.
• If you input an incorrect number, press RETURN
switch (1), and you can clear an input character at a
time.
• If RETURN switch (1) is pressed while no number is entered, the display returns to the standard
screen.
2. After inputting a selected item number, press ENTER
switch (2).

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OPERATION EXPLANATION OF COMPONENTS

3. “Do you send Numeric Input?” When this message is dis-

played, press ENTER switch (2) again.
The input value will be sent out.
To cancel, press RETURN switch (1).
The input number is cleared.

REMARK
If the message is replied, “Numeric Input (Done)” is displayed
for it.

OTHER FUNCTIONS OF MACHINE MONITOR

Confirm the service meter or odometer when the starting switch key is set to
OFF position
The service meter and odometer can be displayed even if the machine monitor is not turned ON.
1. Press UP switch (2) while holding down DOWN switch (1)
when the starting switch is in OFF position.

Service meter (A) and odometer (B) are displayed while

both switches are held down.
NOTICE
If the monitor screen is displayed during other operations
while the starting switch is at OFF position, there is proba-
bly a failure in the equipment, so ask your Komatsu dis-
tributor for inspection.

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EXPLANATION OF COMPONENTS OPERATION

SWITCHES

g0032100

(1) ECSS switch (2) Front working lamp switch

3-92
OPERATION EXPLANATION OF COMPONENTS

(3) Engine shutdown secondary switch (18) Rear heated wire glass switch
(4) Speed range selector switch (19) Emergency HST pump drive switch
(5) Hazard lamp switch (20) Max. traction switch
(6) Horn switch (21) PCS (Proportional Control Switch)
(7) Lamp switch (22) Directional selector switch
(7) Turn signal lever (23) Work equipment lock switch
(7) Dimmer switch (24) Travel speed control dial
(8) Parking brake switch (25) Traction control switch
(9) Rearview monitor brightness adjustment switch (26) Directional selector switch actuation switch
(10) Cigarette lighter (27) Attachment selector switch (if equipped)
(11) Starting switch (28) Remote positioner switch
(12) Front wiper switch (29) 2-stage low idle switch
(13) Rear wiper switch (30) Quick coupler (if equipped)
(14) Monitor brightness selector switch (For details of Quick coupler,
(15) Beacon lamp switch (if equipped) see HANDLE HYDRAULIC TYPE QUICK COUPLER
(16) Rear working lamp switch in Chapter ATTACHMENTS AND OPTIONS)
(17) Room lamp switch

STARTING SWITCH
Starting switch is used to start or stop the engine.
(A): OFF position
The key can be removed from the starting switch, the electrical
current to the electrical system is cut, and the engine stops. In
addition, the parking brake is applied automatically.
(B): ON position
Electric current flows through the charging and lamp circuits.
Keep the switch at this position while the engine is running.
When the ambient temperature is low during engine startup,
the engine preheating pilot lamp lights up and engine preheat-
ing starts automatically.
This preheating time depends on the ambient temperature during engine startup.
When the engine preheating pilot lamp lights up, wait for a while. When it goes out, then turn the starting key to
the START position.
(C): START position
This is the position to start the engine. Hold the key at this position while cranking the engine. Release your
hand off the key immediately after the engine has been started. The key returns to ON position (B).
(D): Manual preheat position
In cold weather, you can increase the engine preheating time longer than the automatic preheating time. To in-
crease it, turn the starting switch key to this position.
When you release your hand, the switch returns to position (A). Immediately turn the key to position (C) and
start the engine.

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EXPLANATION OF COMPONENTS OPERATION

CIGARETTE LIGHTER
The cigarette lighter is used to light cigarettes.
When the cigarette lighter is pushed in, it will return to its origi-
nal position after a few seconds, so pull it out to use it.
If the cigarette lighter is removed, the socket can be used as an
85 W (24 V x 3.5 A) power supply.
NOTICE
This cigarette lighter is for 24 V. Do not use this as a power
supply for 12 V equipment.

LAMP SWITCH
The lamp switch is used to light up the headlamps, clearance
lamps, tail lamps, and machine monitor.
Position (a): OFF
Position (b): Clearance lamps, tail lamps, and machine monitor
light up.
Position (c): Headlamps light up together with the lamps lit in
position (b).
REMARK
The lamp switch can be operated regardless of the turn signal
lever position.

DIMMER SWITCH
The dimmer switch is used to switch the headlights between
high and low beams.
Position (L): Low beam
Position (H): High beam

TURN SIGNAL LEVER

The turn signal lever is used to operate the turn signal lamp.
Position (L): The left turn (when the lever is pushed forward).
Position (N): OFF
Position (R): The right turn (when the lever is pulled backward).
REMARK
• When the lever is operated, the turn signal pilot lamp also
flashes.
• The lever returns automatically when the steering wheel is
turned back. If the lever does not return, move it by hand.

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OPERATION EXPLANATION OF COMPONENTS

HORN SWITCH
If you press the horn switch, the horn sounds.

TRAVEL SPEED CONTROL DIAL

The travel speed control dial is used to freely set the maximum
travel speed at the 1st speed range.
By turning the dial clockwise, the setting of maximum travel
speed becomes higher, and by turning the dial counterclock-
wise, the setting becomes lower.
The maximum travel speed may vary depending on the condi-
tions of use or on road surface condition.

Tire installed Max. speed ( km/h)

Standard tire (20.5R25☆) 1.0 to 13.0

MONITOR BRIGHTNESS SELECTOR SWITCH

The monitor brightness selector switch is used to select the
brightness (luminosity) of the machine monitor and rear view
monitor while lamp switch is turned ON.
When operating the machine with the headlamp lighting up dur-
ing the day, if this switch is set to Day mode, monitor screen
does not loose the brightness.
(A) Day position
The monitor screen is set to the day mode.
(B) Night position
The monitor screen is set to the night mode.
REMARK
When the lamp switch is turned to OFF position, operating this switch does not change the brightness.

REAR VIEW MONITOR BRIGHTNESS ADJUSTMENT SWITCH

The rear view monitor brightness adjustment switch is used to
adjust the brightness of the rearview monitor.
If you release your hand from the switch, it automatically re-
turns to its original position.
The brightness in the day and night modes can be adjusted in-
dividually.
Position (A)
The rearview monitor becomes brighter.

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EXPLANATION OF COMPONENTS OPERATION

Position (B)
The rearview monitor becomes darker.

PARKING BRAKE SWITCH

k WARNING
When parking or leaving the machine, always apply the parking brake.
Keep depressing the brake pedal until the parking brake pilot lamp lights up on the machine monitor
even when the parking brake switch has been turned ON.

NOTICE
• Do not use the parking brake switch during traveling except for an emergency. The parking brake
may be damaged and a serious accident may result. Stop the machine, and then apply the parking
brake.
• If the parking brake was used as a secondary brake when the machine was traveling at high speed,
ask your Komatsu distributor for inspection of the parking brake system.
The parking brake switch is used to apply the parking brake.
Position (A): ON (actuated); The parking brake is applied, and
the parking brake pilot lamp lights up on the monitor.
Position (B): OFF (released); The parking brake is released.
REMARK
• When the parking brake has been applied, the machine
does not move even if the directional lever is operated.
• When the directional lever is shifted to F (forward) or R (re-
verse) position while the parking brake is applied, the cen-
tralized warning lamp lights up and the alarm buzzer
sounds.
• Start the engine after turning the parking brake switch to
ON position.

FRONT WIPER SWITCH

If rotary switch (E) of the front wiper switch is rotated, the front
windshield wiper operates.
If push button (F) is pressed, washer fluid is sprinkled on the
front window glass while the push button is held down.
The switch position can be checked by the position of round
mark (G).
Position (A): (OFF) Wiper is stopped.
Position (B): (INT) Wiper moves intermittently.
Position (C): Wiper moves at low speed.
Position (D): Wiper moves at high speed.

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OPERATION EXPLANATION OF COMPONENTS

REAR WIPER SWITCH

When turning the lever (E) of the rear wiper switch, the rear
wiper operates.
Position (A): Washer fluid is sprayed out. When you release
your hand, it returns to position (B).
Position (B): (OFF) Wiper is stopped.
Position (C): Wiper operates intermittently.
Position (D): Wiper operates and washer fluid is sprayed out.
When you release your hand, the switch returns to position
(C).
REMARK
When the rear wiper switch is in the position (C) and the direc-
tional lever or directional selector switch is in the position R (re-
verse), the rear wiper operates continuously.

ROOM LAMP SWITCH

NOTICE
If the room lamp is left to be turned on, the batteries may be exhausted. Always turn the switch to OFF
position after using room lamp.
The room lamp switch illuminates the room lamp.
Position (A): OFF (goes out)
Position (B): Lights up when cab door opens.
Position (C): ON (lights up)
REMARK
• The room lamp lights up even when the starting switch is
at OFF position. When leaving the operator's seat, set to
position (A) or (B).
• When operating the machine with the cab door fully
opened, set the switch to position (A).

BEACON LAMP SWITCH

(if equipped)
The beacon lamp switch is used to turn on or off the beacon
lamp.
Position (A): ON
Position (B): OFF

REAR WORKING LAMP SWITCH

k WARNING
The working lamps must be turned off when the machine is traveling on a public road.

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EXPLANATION OF COMPONENTS OPERATION

Use the rear working lamp switch to light up the rear working
lamps.
Position (A): The working lamps light up.
Position (B): The working lamps go out.
When position (A) is pressed, the pilot lamp lights up, and the
working lamps turn ON.

ECSS SWITCH
k WARNING
• If the ECSS (Electronically Controlled Suspension System) switch is turned on during travel or with
the work equipment raised, the machine starts moving instantly. Take care.
• If the machine is operated with the ECSS switch ON, the work equipment may start moving at the
moment when the ECSS is actuated. Take care.
• Never turn on the ECSS switch during inspection or maintenance. There is a danger that the work
equipment may move.

NOTICE
• Before operating the ECSS switch, be sure to stop the machine and lower the work equipment to
the ground.
• When performing inspection or maintenance, lower the work equipment to the ground first, press
the ECSS switch to OFF position, then start the work.
• Keep the ECSS switch turned off during leveling work.
The ECSS switch is used to turn on and off the ECSS.
Position (A): ON
The pilot lamp lights up and the ECSS operates.
Position (B): OFF
The ECSS does not operate.
REMARK
• The ECSS absorbs the machine vibration during travel
with the hydraulic spring effect of the accumulator to attain
smooth high speed travel.
• If the travel speed becomes 5 km/h or more, the ECSS op-
erates automatically. If the travel speed becomes 4 km/h or
less, the ECSS stops the operation automatically.
• The effect of the ECSS decreases while the machine is in
the posture that the bucket is at TILT end and it touches
the stopper on the boom.
• Slightly operate the bucket toward DUMP side to release it
from the stopper of the boom, and then the effect of the
ECSS increases.
• To adjust the travel speed of when it is operated or not,
consult your Komatsu distributor.

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OPERATION EXPLANATION OF COMPONENTS

FRONT WORKING LAMP SWITCH

k WARNING
The working lamps must be turned off when the machine is traveling on a public road.

Use the front working lamp switch to light up the front working
lamps.
Position (A): The working lamps light up.
Position (B): The working lamps go out.
When position (A) is pressed, the pilot lamp turns ON, and the
working lamps turn ON.

HAZARD LAMP SWITCH

k WARNING
When the machine is traveling normally, do not use this switch as it can mislead another vehicles.

Use the hazard lamp switch when you need to park the ma-
chine on a road due to machine failure or during emergency
only.
Position (A): The turn signal lamps and the turn signal pilot
lamp flash.
Position (B):The lamps go out.

DIRECTIONAL SELECTOR SWITCH

The directional selector switch is used to set the travel direction
to FORWARD, NEUTRAL, and REVERSE.
Position (F): FORWARD
Position (N): NEUTRAL
Position (R): REVERSE
The directional selector switch operates only when all of the fol-
lowing conditions are met.
• The directional lever is in NEUTRAL position (N).
• The directional selector switch actuation switch is in ON
position.

REMOTE POSITIONER SWITCH

The remote positioner switch is used to freely set the stopping position of the boom and bucket.

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EXPLANATION OF COMPONENTS OPERATION

If you release your hand from the switch, it automatically re-

turns to its original position.
Position (A): Sets or cancels the stopping position of boom.
For the setting and canceling method of the remote positioner,
see “REMOTE POSITIONER (3-201)”.

2-STAGE LOW IDLE SWITCH

Pressing the 2-stage low idle switch increases the engine idle
speed.
Position (A): ON
Position (B): OFF

REAR HEATED WIRE GLASS SWITCH

When pressing the switch for rear window glass with heated
wire, the rear heated wire glass is turned on to clear the glass.
Position (A): ON (Clearing the glass)
Position (B): OFF
When position (A) is pressed, the pilot lamp lights up to turn it
on.

WORK EQUIPMENT LOCK SWITCH

k WARNING
• When leaving the operator's seat, be sure to lock the work equipment by pressing the work equip-
ment lock switch (the pilot lamp lights up). If the work equipment is not locked and the multifunc-
tion mono-lever (A) is touched by mistake, it may lead to serious accident.
• If the work equipment is not securely locked, it can start moving and cause a serious personal in-
jury or death. Check that the pilot lamp is lit.
• Before operating the work equipment lock switch, make sure that the multifunction mono-lever (A)
is in “HOLD” position.
• When operating the work equipment lock switch, be sure not to touch the multifunction mono-lever
(A).

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OPERATION EXPLANATION OF COMPONENTS

The work equipment lock switch is a device used to lock the

operation of the work equipment.

The work equipment is locked (the pilot lamp lights up) or un-
locked (the pilot lamp goes out) each time you press the posi-
tion (B) of the switch.
If you release your hand from the switch, it automatically re-
turns to its original position.
Even if you may turn the starting switch to OFF position with
the work equipment unlocked (pilot lamp goes out), the work
equipment is locked (pilot lamp lights up) if you turn the starting
switch to ON position again.

EMERGENCY HST PUMP DRIVE SWITCH

NOTICE
• Use the emergency HST pump drive switch only in an abnormal case.
• Ask for repair of the problem part as soon as possible.
• When the directional lever is in other than NEUTRAL position (N), if the switch is operated to the
position (B), the machine starts to travel at the same time. Take care.
The emergency HST pump drive switch is used to enable driving the machine temporarily if the machine cannot
travel due to the trouble in the pump control system (the HST system caution lamp lights up in red and action
level “L03” is displayed).
When you release your hand from the switch, it returns auto-
matically to position (A). Keep the switch held at position (B)
when operating.
Position (A)
OFF (when normal)
Position (B)
ON (in an emergency)

Setting the switch to position (B) makes the alarm buzzer

sound and lights up the emergency HST pump drive pilot lamp
on the machine monitor.
If the machine cannot travel due to the trouble in the pump con-
trol system, operate the directional lever to F (FORWARD) or R
(REVERSE) position while holding the switch in position (B),
and the machine travels forward and reverse at low speed.
Move the machine to a safe place, stop the engine, and per-
form the inspection and maintenance.

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EXPLANATION OF COMPONENTS OPERATION

REMARK
If you release the emergency HST pump drive switch during traveling, the machine may stop abruptly.
Release the accelerator pedal, depress the brake pedal, and release the switch after the machine stops.

MAX. TRACTION SWITCH

With the Max. traction switch, the traction control or S mode is
canceled.
The traction control switch is used to turn on the traction control
or to select the S mode.
Press the Max. traction switch while the traction control is
turned on or the S mode is selected, then the traction control or
the S mode is canceled, and the maximum rim pull increases.
The traction level display on the machine monitor indicates
“MAX”.

To turn on the traction control or the S mode again, press the

Max. traction switch or change the directional lever position.
REMARK
Use this switch to increase the rim pull further for the scrape-up work.

PCS (PROPORTIONAL CONTROL SWITCH)

(if equipped)
PCS (Proportional Control Switch) is used to operate the at-
tachment.
Position (A): Extend the left cylinder (retract the right cylinder)
Position (B): HOLD
Position (C): Extend the right cylinder (retract the left cylinder)

TRACTION CONTROL SWITCH

With the traction control switch, the traction control can be ac-
tuated and the maximum rim pull can be changed.

Press the position (A).

Each time the position (A) is pressed, the following 2 conditions are switched.
• Traction control is OFF (MAX).
• Traction control is ON (“Auto” or “Level 1” to “Level 5”).
Press the position (A) and release your hand from it, it automatically returns to the position (B).

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OPERATION EXPLANATION OF COMPONENTS

The current traction control operating state is displayed at the

traction level display of the machine monitor. For details of the
operating state, see the table.
You can select the maximum rim pull when the traction control
is turned on from “Auto”, “Level 1” to “Level 5” with the traction
level selection function of the machine monitor.
For the selecting method of the traction level, see “TRACTION
LEVEL SELECTION”.
Position (C): S mode
S mode is actuated.
When the S mode is actuated, the S mode operation pilot lamp on the machine monitor lights up.
When the S mode is actuated, tires will not easily slip and operation on a very slippery ground such as a snow
removal work can be performed easily, because an appropriate driving force is obtained.
Moreover, the machine may start smoothly and a sudden start at forward travel may not occur.
REMARK
• Select the traction level “Auto” for loading work. The rim pull is automatically adjusted to the optimum one to
reduce the fuel consumption and decrease the slipping of tires as well.
• If you select the most suitable maximum rim pull for the work condition by using the traction control switch
and with the traction level selection function, you may increase the work efficiency and decrease the slip-
ping of tires.
• If the rim pull is too large for the work condition, the boom may not easily be raised and tires may easily
slip. If tires frequently slip, the work efficiency may decrease and the service life of the tires is shortened.
• If the rim pull is too small for the work condition, the bucket cannot be sufficiently pushed into the target
material of loading and the work efficiency may decrease.

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EXPLANATION OF COMPONENTS OPERATION

Traction control operating state

Features
Traction control
Switch position Display on monitor Target material of
setting Rim pull Road conditions
loading

Suitable on the
Suitable for heavy
Press (A). - Large ground not slip-
target material.
pery.
(*1)

Can be applied for loading work by au-

Automatic ad-
tomatic adjustment.
Auto justment
Reduces the fuel consumption when
(*2)
(*3) traveling at 3rd or 4th.

Automatic ad-
justment Can be applied for loading work by au-
Auto
tomatic adjustment.
(*2)

Suitable for loading heavy target mate-

rial and on the ground not slippery.
Large
Level 5 (High) In the stall range (when travel speed is
↑ around 0 km/h {0 MPH} ), the equiva-
(*1) │ lent rim pull when traction control is
OFF (MAX) can be performed.
│
(B)
│
Suitable on the
Level 4 │ Suitable for heavy
ground not slip-
target material.
│ pery.
↑
│ ↑
│
Level 3 │ │
│
│ │
↓
│ ↓
Suitable for light
Level 2 │ Suitable on the
target material.
slippery ground.
│
↓
Small Use this to keep the rim pull at small
Level 1 (Low)
level for a particular purpose.

Tires will not easily slip and operation on a slippery

ground such as a snow removal work can be per-
formed easily, because an appropriate driving force is
(C) - obtained.
Moreover, the machine may start smoothly and a sud-
den start at forward travel may not occur.

(*1): When the traction control is set to OFF (MAX), the maximum rim pull can be performed over all speed
ranges. When the machine is operated in the stall range (when the travel speed is around 0 km/h), however, the
machine operation can become easier by setting the traction control to ON when tires slip.
(*2): Optimum control of the HST pump and HST motor according to the work load is performed and it can re-
strain the fuel consumption.
(*3): It is set when the Eco Traveling mode is set to “ON”. To reduce the fuel consumption when traveling at 3rd
and 4th speed, we recommend to set the Eco Traveling mode “ON”.

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OPERATION EXPLANATION OF COMPONENTS

Switch operation and transition of traction mode

(*4): Select the traction level on the machine monitor.

(*5): Press (A) lightly to return it to the position (B).

DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH

The directional selector switch can be enabled by setting the
directional selector switch actuation switch to "enable".
Position (A): Directional selector switch is enabled.
Position (B): Directional selector switch is disabled.
REMARK
• When setting the directional selector switch actuation
switch to "disable", set the directional lever and the direc-
tional selector switch to NEUTRAL position. The direction-
al selector switch actuation switch does not function if they
are in the position other than NEUTRAL.
• Even when the directional selector switch is functioning, if
the directional lever is operated, the directional lever oper-
ation is given priority.

ATTACHMENT SELECTOR SWITCH

(if equipped)
The attachment selector switch is used to switch the bucket po-
sitioner and fork positioner.
(A) Bucket positioner
Set to this position when using the bucket.
(B) Fork positioner
Set to this position when using the fork.
REMARK
When the fork positioner is selected, the PZ auto tilt-in function
is not effective.

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EXPLANATION OF COMPONENTS OPERATION

SPEED RANGE SELECTOR SWITCH

The speed range selector switch is used to change the travel
speed range of the machine.
Position (a): 1st speed
Position (b): 2nd speed
Position (c): 3rd speed
Position (d): 4th speed
REMARK
When traveling at high speed with 3rd or 4th speed range (trav-
el speed 8 km/h or more), even if the speed range is shifted to
1st or 2nd, the speed range does not change to 1st or 2nd in
order to prevent HST motor overrunning.
In such case, the centralized warning lamp lights up and the
alarm buzzer sounds.
To cancel the alarm buzzer, perform the following.
• Reduce the travel speed to 7 km/h or less. The speed
range becomes 1st or 2nd, and the alarm buzzer is can-
celed.
• Return the speed range selector switch to 3rd or 4th.

ENGINE SHUTDOWN SECONDARY SWITCH

NOTICE
The engine shutdown secondary switch is used to stop the engine when the starting switch is turned to
OFF position but the engine does not stop.
• Use the engine shutdown secondary switch only in an emergency.
Contact your Komatsu distributor for repair immediately when there is any abnormality on this
switch.
• If the engine shutdown secondary switch is set to STOP ENGINE position by mistake while the ma-
chine is operating normally, “Engine Shutdown Secondary SW in Operation” is displayed on the
machine monitor.
If “Engine Shutdown Secondary SW in Operation” is displayed on the machine monitor, check that
the switch cover is closed and the switch is in NORMAL position. If not, return it to NORMAL posi-
tion.
Lower the work equipment to the ground, push the work equipment lock switch to lock the work equipment, turn
on the parking brake switch, and turn the starting switch to OFF position.
If the engine does not stop, operate the engine shutdown secondary switch according to the following proce-
dure.
1. Raise cover (1) and open it.
There is a switch under the cover.

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OPERATION EXPLANATION OF COMPONENTS

2. Pull up the switch, and the engine stops.

(a) STOP ENGINE: When abnormal (switch is set up)
(b) NORMAL: When normal (switch is set down)
• When cover (1) is closed, the engine shutdown secon-
dary switch automatically returns to NORMAL position
(b).
• When the starting switch is turned to ON position
while the engine shutdown secondary switch is in
STOP ENGINE position (a), “Engine Shutdown Sec-
ondary SW in Operation” is displayed on the machine
monitor.
If this screen is displayed, return the engine shutdown
secondary switch to NORMAL position.

CONTROL LEVERS AND PEDALS

(1) Steering tilt lock lever (4) Accelerator pedal

(2) Directional lever (5) Brake pedal
(3) Multifunction mono-lever

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EXPLANATION OF COMPONENTS OPERATION

DIRECTIONAL LEVER
The directional lever switches the machine travel between the
forward and reverse.
The engine does not start if the directional lever is not in NEU-
TRAL position (N).
In such case, the centralized warning lamp lights up and the
alarm buzzer sounds.
Start the engine after turning the directional lever to NEUTRAL
position (N).
Position (F): FORWARD
Position (N): NEUTRAL
Position (R): REVERSE
REMARK
Do not maintain the directional lever at the intermediate position between positions (F) and (N), or between po-
sitions (N) and (R).

MULTIFUNCTION MONO-LEVER
The multifunction mono-lever is used to operate the boom and
bucket.
NOTICE
Do not use “FLOAT” position when lowering the bucket.
Use “FLOAT” for leveling work.

Position (a): RAISE

When the multifunction mono-lever is pulled further from the
“RAISE” position, the lever stops in that position.
When the remote boom positioner is enabled, the boom stops
at the preset position and the lever returns to “HOLD” position
at the same time.
When the remote boom positioner is disabled, the boom stops
at the highest position and the lever returns to “HOLD” position
at the same time.
Position (b): HOLD
The boom and bucket remain in the positions where they are stopped.
Position (c): LOWER
Position (d): FLOAT

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OPERATION EXPLANATION OF COMPONENTS

The boom moves freely under external force. When the lever is set to “FLOAT” position, the lever stops in that
position.
Position (e): TILT
When the multifunction mono-lever is pulled further from the
“TILT” position, the lever stops in that position. When the buck-
et reaches the position preset by the bucket positioner, the lev-
er returns to the “HOLD” position.
Position (f): DUMP

STEERING TILT LOCK LEVER

k WARNING
Stop the machine before adjusting the tilt of the steering wheel. If this operation (adjustment) is per-
formed while the machine is moving, serious personal injury or death can result.

The steering tilt lock lever is used to fix the position of the
steering wheel.
(F) FREE position:
The steering wheel is allowed to move back and forth, and up
and down.
(L) LOCK position:
The steering wheel is fixed in the position.
The adjustable range is shown below.
Vertical adjust- When 0 mm Top to 40 mm
ment
Tilt adjustment 0 to 129 mm 0 to 162 mm

NOTICE
Do not operate the steering tilt lock lever repeatedly with an excessive force. The lever can be loosened
or its angle can be displaced. In such case, ask your Komatsu distributor for inspection.

BRAKE PEDAL
k WARNING
• Use the engine brake during downhill travel.
The brake pedals installed on right and left sides of the steering post provide the same function.
• Do not depress the brake pedal repeatedly more than necessary. Excessive use of the brake may
cause the heat-up of the brake degrading its function, and may result in serious personal injury or
death.
• Do not put your foot on the brake pedal unnecessarily.

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EXPLANATION OF COMPONENTS OPERATION

NOTICE
Frequent braking increases the axle oil temperature. As a result, the alarm buzzer may sound and the
warning lamp may light up for protection of the brake discs. Observe the following ways of operation to
prevent the increase of the axle oil temperature.
• Try to avoid high speeding and sudden braking.
• Try to apply the brake on and off. Try not to apply the brake continuously.
• Try gradual acceleration and braking rather than sudden acceleration and braking.
• When traveling downhill, use a low speed range so that the engine braking works well.
The brake pedal is used to apply the brakes.
Inching function
When depressing the brake pedal lightly, the inching function of
HST actuates. Accordingly, you can decelerate and stop the
machine without decreasing the engine speed.
Use the inching function when the machine approaches the
dump truck while raising the boom.
REMARK
When performing the work by decelerating and stopping the
machine with the brake pedal and accelerator pedal, use the
L.H. brake pedal because it is more convenient.

ACCELERATOR PEDAL
The accelerator pedal is used to adjust the speed and output of
the engine.
It freely controls the engine from low idle to high idle.

OTHER COMPONENTS
METHOD FOR OPENING AND CLOSING CAB DOOR
k CAUTION
• Always check that the cab door is locked in position,
both when it is open and when it is closed.
• Always place the machine on a level ground when
opening or closing the door.
Avoid opening or closing the door on a slope, since
there is a danger that the operating effort may sudden-
ly change.
• Hold the door handle and knob whenever opening or
closing the door.
• Be careful not to get your hands caught between the
front pillar or center pillar.
• When there is anyone inside the cab, always call out a
warning before opening or closing the door.

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OPERATION EXPLANATION OF COMPONENTS

CAB DOOR HANDLE

While the key is not in the lock position, pull right side (1) of the
door handle with the right hand, and push left side (2) with the
thumb, and the door opens to the full open position,

OPEN HANDLE FOR CAB L.H. DOOR

Hold open handle (3), and the door opens to the full open posi-
tion.

OPEN LOCK FOR CAB L.H. DOOR

Use this to fix the door in position after opening it or when getting on and off the operator's cab.
1. Push the door against catch (1) to lock it in position.
2. When keeping the door open, fix it securely to the catch.
3. When getting on or off the machine, hold the inside hand-
rail.

4. When closing the door, push down knob (2) to release the
catch.

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EXPLANATION OF COMPONENTS OPERATION

UNLOCK KNOB FOR SLIDE WINDOW OF CAB

Use this to open and close the door window glass up and
down.
Grip unlock knob (1) to release the lock, then move it to the
lower LOCK position and release it.
There are 3 stages for LOCK position (A).

OPEN KNOB FOR ALTERNATE EXIT OF CAB

k CAUTION
• The door on the right side of the cab is provided as an alternate exit for use when the operator can-
not get out through the door on the left side. Do not use this door to get on and off the operator's
cab normally.
• Do not operate the machine with the door open full or halfway.
The door may suddenly close or open full, and it is very dangerous.
Never operate the machine with the door open.
• Always operate the machine while the door is fully closed or locked half open.

Alternate exit door closed fully or locked half open

• When door knob (1) is pressed down completely, the door
is locked with fully closed state.
When cooling or heating the cab, keep the door locked
and fully closed with this function.

• If the door knob (1) is pulled up, the door is locked half
open.
When talking to a person on the right outside of the ma-
chine, keep the door locked half open with this function.

Unlock in emergency
If the door on the left side of the cab does not open or it is dangerous to get off the cab through the left side
door, release the alternate exit door knob on the right side to open the right side door fully and get off the cab.

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OPERATION EXPLANATION OF COMPONENTS

1. Pull up door knob (1).

2. Hold door knob (1) and pull it toward the rear of the ma-
chine.

3. Remove the guide rail of the door knob from guide pin (2)
fixed to the cab and unlock the right side door.

4. Open the right side door wide and go out.

To return the door knob to the locked state, grip door knob (1)
and pull it toward the rear of the machine.
Match the guide rail of the door knob with the guide pin on the
guide cab side, and push in the door knob toward the front.
Check that the guide pin is inserted into the guide rail securely,
and push in and fix door knob (1) to the lock position.

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EXPLANATION OF COMPONENTS OPERATION

NOTICE
If the door is closed without holding door knob (1), the
plastic part of the door knob hits against guide pin (2) on
the cab side and may be broken.
Always close the door while holding door knob (1).

CAP AND COVER WITH LOCK

Use the starting switch key to open and close the locks on the caps and covers.
For the locations and opening or closing method of the cap with lock and cover, see “LOCK (3-208)”.
Insert the key as far as it will go to the shoulder (A) and turn it.
If the key is turned when it is not inserted all the way to the
end, it may break.

COOL BOX
Drink, hand towel, etc. can be kept cold during the cooling op-
eration.
They can be kept warm during the heating operation.
Do not put things which smell or break easily or leak water, etc.
in this box.
Do not use this box as a holder for small objects.

CUP HOLDER
The cup holder is located at the rear left of the operator's seat.

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OPERATION EXPLANATION OF COMPONENTS

ASHTRAY
This is on the right side of the operator's seat.
Always extinguish your cigarette before putting it in the ashtray
and be sure to close the lid.

NOTICE
While removing the ashtray, if it is stuck in the console
cover and hard to be removed, open lid (A) of ashtray, then
hold the ashtray body (B) and twist it to remove.
If you hold lid (A) of ashtray and twist it, the ashtray may
break.

POWER SUPPLY OUTLET

24 V power supply
NOTICE
Do not use this as a power supply for 12 V equipment.
This will cause failure of the equipment.
When the cigarette lighter (1) is removed, its socket can be
used as a 24 V power supply.
The maximum capacity is 85 W (24 V x 3.5 A).
REMARK
Use 24 V power supply while the engine is running.

12 V power supply

Power supply take-out port (2) at the rear left of operator's seat
can be used as a 12 V power supply.
The maximum capacity is as follows.
• When it is used at one place: 120 W (12 V x 10 A)
• When it is used at both places: 176 W(12 V x 14.7 A) in to-
tal
REMARK
Use 12 V power supply while the engine is running.

FUSE
NOTICE
When replacing the fuse, be sure to turn the starting switch to OFF position and, after confirming that
the system operating lamp is not lit, set the battery disconnect switch key to OFF position.
The fuses protect the electrical component and wiring from burning out.

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EXPLANATION OF COMPONENTS OPERATION

If the fuse is corroded, or loose in the fuse holder, or looks white powdery, replace it.
Replace the fuse with the one of the same capacity.
Should the fuse is blown, investigate the cause and take necessary actions.
Inside rear console box
Loosen the knobs (1) (2 places), then remove the cover (2).
Fuse boxes are A, B, and C inside.

Fuse capacities and circuit names

Fuse box A
Fuse
No. Name of circuit
capacity
(1) 20 A Starting switch
(2) 10 A Hazard lamp
(3) 15 A HST
(4) 30 A Engine control
(5) 10 A Monitor display
(6) 15 A Radio
(7) 10 A Auxiliary power supply
(8) 10 A L.H. headlamp
(9) 10 A R.H. headlamp
(10) 10 A Turn signal lamp
(11) 10 A Backup lamp and brake lamp
(12) 15 A HST control
(13) 10 A Boom
(14) 20 A Wiper
(15) 20 A Radio

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OPERATION EXPLANATION OF COMPONENTS

Fuse box B
Fuse
No. Name of circuit
capacity
(1) 20 A Air conditioner blower
(2) 5 A Air conditioner compressor
(3) 20 A Revolving lamp
(4) 20 A Heated wire glass
(5) 10 A Load meter
(6) 20 A Auxiliary power supply
(7) 10 A DC converter
(8) 10 A Parking brake
(9) 20 A Horn
(10) 10 A L.H. clearance lamp
(11) 10 A R.H. clearance lamp
(12) 20 A Front working lamp
(13) 20 A Rear working lamp
(14) 5 A Starting switch, accessory

Fuse box C
Fuse
No. Name of circuit
capacity
(1) 20 A Smart sensor
(2) 10 A Smart sensor
(3) 10 A DEF heater
(4) 20 A DEF heater

SLOW-BLOW FUSE
NOTICE
When replacing the slow-blow fuse, be sure to turn the starting switch to OFF position and, after con-
firming that the system operating lamp is not lit, set the battery disconnect switch key to OFF position.

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EXPLANATION OF COMPONENTS OPERATION

When the starting switch is turned to ON position, if the power

is not supplied, the slow-blow fuse may be blown. Check the
slow-blow fuse and replace it if necessary. Check or replace it.
The slow-blow fuse is on the side of the engine on the left side
of the machine as shown in the figure.
Remove the cover (1), open the cover (2), and check the slow-
blow fuse.
If any trouble occurs on the slow-blow fuse, replace the slow-
blow fuse by referring to “MAINTENANCE”, “METHOD FOR
REPLACING SLOW-BLOW FUSE”.
Slow-blow fuse
(A) 80 A: Machine's power supply 1
(B) 120 A: Machine's power supply 2
(C) 120 A: Engine preheater power supply
(D) 80 A: Battery power supply (starting switch, hazard)

FRAME LOCK BAR

k WARNING
• When performing the maintenance or transporting the machine, always set the frame lock bar to
LOCK position.
• When driving the machine, always set the frame lock bar to FREE position.
If the frame lock bar is not in FREE position, the steering becomes inoperative and this may lead to
serious personal injury or death.

This is a device used to lock the front and rear frames to pre-
vent the machine from being articulated during the mainte-
nance or transporting the machine.
(L) LOCK position
It is used for maintenance and transportation
The front frame and the rear frame are locked so that the ma-
chine body is not articulated.
(F) FREE position
It is used for normal operation.
The machine body is articulated.

METHOD OF USING TOWING PIN

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OPERATION EXPLANATION OF COMPONENTS

1. Position the protrusion (2) of towing pin (1) with groove (3)
of the counterweight, and insert it.

2. Turn the handle (4) of towing pin (1) clockwise by 60 °.

Turn it until it hits the wall (5) of the counterweight.
3. When removing it, perform the procedure in the reverse or-
der.

BATTERY DISCONNECT SWITCH

k CAUTION
• Do not operate the battery disconnect switch while the engine is running.
The large current generated by the alternator may burn the electric parts and cause a fire.
Operate the battery disconnect switch only when the engine is stopped.
• If the battery disconnect switch is turned to OFF position, always remove the switch key.
If someone turns the key to ON position carelessly, this is extremely dangerous.

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EXPLANATION OF COMPONENTS OPERATION

NOTICE
• Keep the battery disconnect switch in ON position except the following cases.
• When the machine is stored for a long time (more than a month)
• When repairing the electrical system
• When performing the electric welding
• When handling the battery
• When replacing the fuse, etc.
• Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit. If
the battery disconnect switch is turned off while the system operating lamp is lit, the data in the
controller may be lost.
• If this switch is turned to OFF position, all the electrical system is cut out and the functions of KOM-
TRAX stop. In addition, the time setting of the clock may be lost. In this case, set the information
again by referring to “CLOCK ADJUSTMENT”.
The battery disconnect switch is used to cut out the electricity
from the battery.
Open the cover (1) of the battery box on the rear right of the
machine, raise the rubber cover (2), and battery disconnect
switch (3) is seen.
REMARK
Operate it while the system operating lamp (4) is not lit.

(O): OFF position

It allows inserting and removing of the switch key (3), and is
used for cutting off the current from the battery.
(I): ON position
The current from the battery flows into the circuit.
Before starting the machine, be sure to set it to this position.

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OPERATION EXPLANATION OF COMPONENTS

REMARK
• If the battery disconnect switch is turned to OFF position,
every electric system of the machine becomes inoperable.
• The memory of the clock of the monitor is lost.
Set it again when using.
• Immediately after the starting switch is turned to OFF posi-
tion, data is saved on each controller.
Before turning the battery disconnect switch to OFF posi-
tion, make sure that the system operating lamp (4) below
the battery disconnect switch is not lit.
• Immediately after the reverse rotation of the fan, power to
the fan reverse solenoid is supplied for some time to pro-
tect the hydraulic motor even if the starting switch is turned
to OFF position.
Before turning the battery disconnect switch to OFF posi-
tion, make sure that the fan is stopped completely.

SYSTEM OPERATING LAMP

The system operating lamp indicates that the controller mount-
ed on the machine is turned ON.
System operating lamp (1) lights up in green when the control-
ler is turned ON and normally goes out in 5 to 6 minutes after
the power for the machine is turned OFF.
Before operating the battery disconnect switch, check that sys-
tem operating lamp (1) is not lit.
NOTICE
If the battery disconnect switch is turned OFF while the
system operating lamp is lit, the data in the controller may
be lost.
REMARK
• Even if the starting switch is in OFF position, the controller may operate. The system operating lamp lights
up in this case, but it is not abnormal.
• After the starting switch has been turned off, the system operating lamp may stay lit for a long time.
In such case, consult your Komatsu distributor.
• While DEF system devices are operating, the system operating lamp lights up to return DEF to the tank.
Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit.

BACKUP ALARM
NOTICE
If water directly hits the backup alarm during the high-pressure machine washing, the water gets in it
and the sound pressure decreases. Do not jet the water over the backup alarm.
This alarm sounds as soon as the machine moves in reverse to
warn the people behind the machine.
The operations to move the machine in reverse are as follows.
• Set the directional lever to REVERSE position.
• Set the directional selector switch to REVERSE position.

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EXPLANATION OF COMPONENTS OPERATION

HANDLING FRONT WIPER

Preventing the damage to the wiper arm bracket
NOTICE
When tilting wiper arm (1) forward, make sure that wiper
blade (2) moves freely.
When tilting wiper arm (1) forward for cleaning cab glass, etc.,
make sure that wiper blade (2) is not locked in the arm (the bot-
tom of the blade is not caught in the arm). If locked, an abnor-
mal external force may apply to the bracket when you tilt the
wiper arm forward, and the bracket may be damaged.

AUTO-GREASING
NOTICE
The auto-greasing system is used only for all connected lubrication points. The other lubrication points
have to be greased manually.
Changing the lubrication interval times
The auto-greasing system is adjusted for the normal use.
The settings when shipping from the factory are as follows.
Lubrication interval: Every 1 hour
Lubrication time: 9 minutes
When changing the settings of the lubrication cycle for the heavy-duty operations, consult your Komatsu distrib-
utor.
Method for operating the auto-greasing system
The pump with grease tank is located at the position as shown
in the figure.
For details, see “CHECKING AUTO-GREASING AND OPERA-
TION METHOD FOR FILLING GREASE (4-44)”.

Turn the starting switch to ON position (B).

The power supply to the grease pump is turned on.
The auto-greasing pilot lamp is lit for 2 seconds.

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OPERATION EXPLANATION OF COMPONENTS

Display and control unit

The display and control unit are protected by a transparent
plastic cover against sprayed water and mechanical damages.
For setting, the cover needs to be removed and remounted af-
terwards.

LED display
(1) Three-digit LED display: Values and operating state
(2) Pause time
(3) Pump operation
(4) Monitoring of system function by means of an external cycle
switch
(5) Without function
(6) Fault message

Push button switch

(1) Turn on display
Display values and parameters
Set values and parameters
(2) Change between setting and display mode
Confirm values
(3) Actuation of manual lubrication
Clear fault message

Three-digit LED display

During normal operation, the display is off. It is activated by
briefly operating one of the two push buttons.
It is used for displaying current values and preset parameters.
In addition, the display is used for operator prompting during
setting of operating parameters.

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EXPLANATION OF COMPONENTS OPERATION

Display Denotation Explanation Control function

t = TIMER The control unit operates as a time Part of lubrication cycle
PA = PAUSE controlled contact maker (TIMER) Input and display value in “hours”
and is in the PAUSE state

c = COUNTER Attention! Not used

PA = PAUSE This mode causes a malfunction.

t = TIMER The control unit operates as a time CONTACT = time during which
CO = CONTACT controlled contact maker (TIMER) the pump is delivering
and is in the pump running time
(CONTACT)
c = COUNTER Attention! Not used
CO = CONTACT This mode causes a malfunction.

C = Cycle Display of beginning of menu

O = OFF “Monitoring settings”
P = Pressure

Monitoring The monitoring functions PS and No system monitoring

OFF CS are deactivated.

Cycle Switch Cycle switch monitoring is activa- The cycle switch is monitored for
ted. the transmission of signals dur-
ing the pump running time (CON-
TACT).
Fault Low Level The minimum level in the grease The control unit is in the FAULT
tank has been reached. mode. The sequence of opera-
tions is stopped.

Fault Cycle Switch No signal from cycle switch during The control unit is in the FAULT
pump running time. mode. The sequence of opera-
tions is stopped.

Operation Hour Meter The subsequently displayed values are the operating hours of the con-
trol unit.

Fault Hour Meter The values displayed in the following are the fault hours which are the
time while the vehicle or machine has been operated in the FAULT
mode.

Block operation Signal from cycle switch missing. Contrary to normal operation, the
control unit is still in the monitoring mode. If the fault continues to exist
for 3 pump running periods, a fault message is displayed.

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OPERATION EXPLANATION OF COMPONENTS

Trouble
Fault hours are added in the fault hour meter and can not be
deleted.
All fault messages are displayed on LED (A) as a collective
fault.
All fault messages can be acknowledged and deleted with but-
tons (B).
The display mode will start with one of two buttons (C).
When grease has leaked from pressurized safety valve (1),
consult your Komatsu distributor.
The pump has an automatic level control. If the grease level
falls below “min” mark, the lubrication process is stopped with
the fault message “FLL” shown on the display.
If fault message “FLL” is displayed, fill up with grease and reset
the fault with button (B).

Fault message
Display Denotation Explanation Control function
Fault Low Level The minimum level in the grease The control unit is in the FAULT
tank has been reached. mode. The sequence of opera-
tions is stopped.

Fault Cycle Switch No signal from cycle switch during The control unit is in the FAULT
pump running time. mode. The sequence of opera-
tions is stopped.

If the fault message will appear again after the reset, consult your Komatsu distributor.

HANDLE REAR VIEW MONITOR

k WARNING
• Never operate any of the switches while traveling. If you do so, there is a danger that you may make
an error in the machine travel operation, or neglect to watch the travel path ahead for safety, and as
a result cause a serious personal injury or death.
• The rearview monitor is an device for supporting a visual check if there is any obstacle in the rear
or the area around the machine. An image appearing on the monitor is limited.
When backing up the machine, be sure to make a visual check, not relying solely on the monitor.
Never rely solely on the monitor when backing up the machine.
• An image on the rear view monitor does not show an actual distance. Drive the machine slowly,
when backing it up.
• The distortion different from the actual state appears on an image on the rearview monitor.
So, look at the center of the screen as a guide.

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EXPLANATION OF COMPONENTS OPERATION

When the machine is backed up and rear view monitor (1) is

set in operation, a monitor screen enables the operator to
check the rear for safety.
REMARK
• The screen may be hard to see in the dark place at night,
but it is not a trouble.
The luminance of the rear view monitor can be adjusted
with rearview monitor brightness adjustment switch (2).
• Guide line (3) is used for checking the machine width and
rear of the machine roughly.
• Guide line (3) does not synchronize with the steering an-
gle. Guide line (3) does not indicate the actual moving di-
rection or travel path.
• Intensity or color of the objects may change because of
the automatic adjustment function of the camera.

HANDLE Komatsu Diesel Particulate Filter (KDPF)

k CAUTION
• Exhaust gas temperature may increase during the aftertreatment devices regeneration and the high
temperature may last after the completion of regeneration.
Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being
burnt.
Also, keep combustible materials away from the exhaust pipe outlet and around the aftertreatment
devices to prevent a fire.
• When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to
the regeneration disable to prevent fire hazards due to highly heated exhaust gas during the after-
treatment devices regeneration.
• Do not leave the operator's seat during the aftertreatment devices regeneration.

KDPF is a device to capture soot in the exhaust gas to purify

the exhaust gas.
If soot is accumulated to a certain level in the filter, a purifica-
tion process to burn the soot is performed automatically to
keep the filtering performance of KDPF high.
This purification process is called the “regeneration”.
If operations which lower the purification function of KDPF con-
tinues for long hours, the regeneration is performed to protect
the KDPF system, regardless of the quantity of the accumulat-
ed soot.
During the KDPF regeneration, aftertreatment devices regeneration pilot lamp (1) lights up on the monitor.

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OPERATION EXPLANATION OF COMPONENTS

REMARK
• Even if aftertreatment devices regeneration pilot lamp (1)
lights up, the machine does not need to be stopped and
the work can be continued, unless when the KDPF soot
accumulation caution lamp (2) lights up.
• Accumulation amount of soot can be checked by soot ac-
cumulation level (3) on the “Aftertreatment Devices Regen-
eration” screen.
Operate the menu switch on the standard screen to dis-
play the “Aftertreatment Devices Regeneration” screen.
• Automatic regeneration against accumulation of soot starts
when the soot accumulation level increases “3” or above,
and stops a while after the soot accumulation level de-
creases to “0”.
The KDPF regeneration is performed automatically. However,
the accumulated soot may not be burnt sufficiently and the fil-
tering function may not be improved under certain operating
conditions.
In that case, KDPF soot accumulation caution lamp (2) lights
up. If this lamp lights up, stop the machine in a safe place and
perform the manual stationary regeneration.
Two types of monitor display require the manual stationary re-
generation, depending on the level of urgency.
When the directional lever is turned to NEUTRAL position (N)
and the parking brake switch is turned to the “ON” position, the
manual stationary regeneration may start automatically to pro-
tect the KDPF.

NOTICE
Do not stop engine when the aftertreatment devices regeneration is activated.
When stopping the engine, stop the aftertreatment devices regeneration first according to “PROCE-
DURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING”, then keep engine run-
ning at low idle for approximately 5 minutes, and stop engine.
When the Action level “L03” lights up in red, and the KDPF soot accumulation caution lamp (2) lights up
in red, engine power deration is activated. To restore engine power, it is necessary to perform “PROCE-
DURE FOR MANUAL STATIONARY REGENERATION”.
If soot accumulated in the KDPF exceed the defined level
without performing “PROCEDURE FOR MANUAL STA-
TIONARY REGENERATION”, the Action level “L04” lights
up in red. Stop the machine immediately and ask your Ko-
matsu distributor.

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EXPLANATION OF COMPONENTS OPERATION

REMARK
• Soot accumulation level (3) can be checked with the “Af-
tertreatment Devices Regeneration” screen. Press the
menu switch on the standard screen to display “Aftertreat-
ment Devices Regeneration” screen of the user menu.
• Since the soot in the filter of KDPF can be burnt by the
high-performance catalyst and high-temperature exhaust
heat, the soot accumulation quantity may decrease even if
the regeneration is not performed, depending on the oper-
ating condition.
• Even when the soot accumulation level is low, the auto-
matic regeneration may be performed and the manual sta-
tionary regeneration may be requested to protect the system.
In particular, if engine is kept running with no load, the regeneration frequency may increase, but this is not
a failure.
• Even just after the regeneration is completed, the soot accumulation level may not be “0”. This is caused by
the accumulated noncombustible material in the exhaust gas and is not a failure.
• Since noncombustible matter which cannot be burnt by the regeneration is accumulated in the filter of
KDPF, the filter needs to be cleaned or replaced at regular intervals.
• The engine speed or engine sound or exhaust sound may change during or after the regeneration. This is
caused by the control for better regeneration and this is not a failure.
• The smell of the exhaust gas is different from that of the conventional diesel engine because of the exhaust
gas filtering function.
• White smoke may be discharged for a short time just after the engine is started or during the regeneration
in the cold season, but this is not a failure.
• Komatsu recommends using Komatsu genuine engine oil for KDPF.
If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF
filters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may
cause failure.
In addition, the regeneration interval may be shortened and the fuel consumption may increase.
• If the mixing ratio of the bio-fuel in the diesel fuel is high, the regeneration of KDPF may become more fre-
quent.

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When the degree of emergency is low

• If KDPF soot accumulation caution lamp (2) lights up in
yellow (action level (4): “L01”), screen (A) is displayed first.
• The action level goes out 2 seconds after and the screen
changes to standard screen (B).
• If the machine is completely stopped, the display switches
to “Aftertreatment Devices Regeneration” screen (C) after
3 seconds only the first time. If, however, the manual sta-
tionary regeneration is not performed, the display returns
to standard screen (B) after 30 seconds.
Then, if the accumulated soot does not decrease, the “Af-
tertreatment Devices Regeneration” screen (C) is dis-
played for 30 seconds every 2 hours.
• If KDPF soot accumulation caution lamp (2) lights up in
yellow, stop the machine in a safe place and perform the
manual stationary regeneration.

When the degree of emergency is high

• KDPF soot accumulation caution lamp (2) lights up in red
and the action level “L03” lights up in red (4).
• If the machine is stopped completely, the screen changes
to the “Aftertreatment Devices Regeneration” screen (E)
after 3 seconds.
Then, the “Aftertreatment Devices Regeneration” screen
(E) and standard screen (D) are automatically displayed
alternately in accordance with machine stop, until the man-
ual stationary regeneration is performed.
• If KDPF soot accumulation caution lamp (2) lights up in
red, immediately stop the machine in a safe place and per-
form the manual stationary regeneration.

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EXPLANATION OF COMPONENTS OPERATION

PROCEDURE FOR MANUAL STATIONARY REGENERATION

k CAUTION
Exhaust gas temperature may increase higher than the
previous models during the aftertreatment devices regen-
eration. Avoid getting near the exhaust pipe outlet and
around the aftertreatment devices to prevent being burnt.
Also, keep combustible materials away from the exhaust
pipe outlet and around the aftertreatment devices to pre-
vent a fire.

The manual stationary regeneration can be performed while

KDPF soot accumulation pilot lamp (1) is lit.
1. Move the machine to a safe place and stop it with engine
running.
2. Check that there is no person or combustible matter
around the machine (particularly in the direction of the ex-
haust gas flow).
3. Release your foot from the accelerator pedal and set the
directional lever to NEUTRAL position (N).

4. Set the parking brake switch to ON position (A) and apply

the parking brake.

5. Press the menu switch to display “Aftertreatment Devices

Regeneration” screen.

6. Select the manual stationary regeneration, check again safety of the surrounding area and make sure the
area is free from irrelevant people or combustible material, then press ENTER switch.
If the machine needs to be moved again to secure safety, move it to a safe place and repeat the procedure
from step 1.

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OPERATION EXPLANATION OF COMPONENTS

REMARK
After ENTER switch is pressed in step 6, the screen
shown in the figure may be displayed. This indicates that
the operations in steps 1 to 3 were not performed correctly
or there is trouble other than KDPF soot accumulation ab-
normality. Check operation of the engine, make sure you
are not depressing the accelerator pedal and check the
position of the directional lever and parking brake switch,
then repeat the procedure from step 5.
If the manual stationary regeneration still cannot be per-
formed, return to the standard screen, press ENTER
switch to check the contents of other occurring troubles,
and take the necessary remedy.
REMARK
• The explanation of the manual stationary regeneration
is displayed in 3 parts on the monitor panel. When
ENTER switch is pressed, the regeneration can be
started immediately, regardless of which part is dis-
played. When RETURN switch is pressed, the display
returns to the standard screen.
• If no monitor switch is operated for 30 seconds, the
explanation display of the manual stationary regenera-
tion is not displayed and the screen returns to the
standard screen. At this time, to display the explana-
tion of the manual stationary regeneration again,
press ENTER switch on the standard screen to dis-
play “Aftertreatment Devices Regeneration” screen.

7. This screen is displayed during the manual stationary re-

generation. It may take more than 30 minutes to complete
the manual stationary regeneration. Do not touch any
switch on the screen or accelerator pedal until the regener-
ation is completed and the standard screen is displayed
again.

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EXPLANATION OF COMPONENTS OPERATION

REMARK
• The progress of the manual stationary regeneration
performed when soot is accumulated can be checked
by the number of lighting lamps of soot accumulation
level (2). The manual stationary regeneration starts at
soot accumulation level “4” or higher and finishes
when all the level lamps go out.
• The manual stationary regeneration for protection of
the system during cold season may start even when
the soot accumulation level is “0” to “3”. In this case,
the soot accumulation level may not decrease, but this
is not a failure. The progress is not displayed on the
monitor during this regeneration. It is completed in ap-
proximately 10 minutes.
• If the accelerator pedal or directional lever is operated,
or the parking brake is released during the manual
stationary regeneration, the regeneration is stopped
automatically. Release your foot from the accelerator
pedal, turn the directional lever to NEUTRAL position
(N), apply the parking brake, and then repeat the pro-
cedure from step 5.
• When the machine needs to be moved during the
manual stationary regeneration, stop the regeneration
temporarily and move the machine, referring to the af-
tertreatment devices regeneration disable and cancel
of regeneration disable procedures described in the
following.
When restarting the manual stationary regeneration,
secure the safety of the machine and around it, then
cancel the regeneration disable.
8. After the manual stationary regeneration is completed, the screen automatically returns to the standard
screen.

PROCEDURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE

SETTING
If there is combustible material around the machine and the active regeneration that increases the exhaust tem-
perature must not be performed, the automatic active aftertreatment devices regeneration can be disabled.
Also, the regeneration in progress can be stopped.
NOTICE
Even if the regeneration is disabled, KDPF soot accumula-
tion caution lamp (1) lights up if soot is accumulated and
the manual stationary regeneration is required.
If KDPF soot accumulation caution lamp lights up, move
the machine to a safe place and perform manual stationary
regeneration.
If the operation is continued without performing the man-
ual stationary regeneration, it may cause the failure of
KDPF or the engine.

WHILE REGENERATION IS NOT BEING PERFORMED: SETTING FOR REGENER-

ATION DISABLE
(When the aftertreatment devices regeneration is not displayed on the standard screen)
1. Press the menu switch on the standard screen.

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OPERATION EXPLANATION OF COMPONENTS

2. Operate the menu switch to select “Aftertreatment Devices

Regeneration” menu (C) and display “Aftertreatment Devi-
ces Regeneration” screen.

3. Select Regeneration Disable and press ENTER switch.

The regeneration function is disabled and the regeneration
is not performed.

REMARK
• When the regeneration is disabled, aftertreatment devices
regeneration disable pilot lamp (1) is displayed with hatch
on the standard screen.
• The setting of the regeneration disable is canceled by turn-
ing starting switch to OFF position. When the automatic re-
generation needs to be kept disabled, perform the above
procedure each time you start the engine.
• During the regeneration to protect the system, even if the
regeneration disable is set, aftertreatment devices regen-
eration pilot lamp (2) may light up, but this does not indi-
cate abnormality. Also, during the regeneration to protect
the system, the regeneration disable cannot be operated.
• When the regeneration is performed to protect the system,
the exhaust temperature is lower than that of when the re-
generation is performed to burn soot, and is almost the
same level as the normal exhaust gas temperature.

WHILE REGENERATION IS BEING PERFORMED: STOPPING REGENERATION

(When the aftertreatment devices regeneration display is lit on the standard screen)
1. When the menu switch is pressed on the standard screen,
“Aftertreatment Devices Regeneration” screen is dis-
played.

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EXPLANATION OF COMPONENTS OPERATION

2. Press ENTER switch after selecting Regeneration Disable,

and then the regeneration stops.
REMARK
The regeneration for protection of the system in cold
weather may not be stopped, but this is not a failure.

PROCEDURE FOR CANCEL OF AFTERTREATMENT DEVICES REGENERATION

DISABLE SETTING
k CAUTION
When canceling the regeneration disable, move the machine to a safe place and check that there is no
person or combustible matter around the machine, and start the cancel operation.

1. When the menu switch is pressed on the standard screen,

“Aftertreatment Devices Regeneration” screen is dis-
played.
(If “Aftertreatment Devices Regeneration” screen is not
displayed, display it by pressing the menu switch several
times.)

2. Select “Cancel of Regeneration Disable” and press EN-

TER switch, and the regeneration disable is canceled.
If soot accumulation level (1) lights up 3 or more, the re-
generation may be started automatically.
REMARK
• When canceling the regeneration disable, release the ac-
celerator pedal, set the directional lever in NEUTRAL posi-
tion (N), set the parking brake switch to “ON” position, then
cancel the regeneration disable.
• The regeneration disable setting is also canceled by turn-
ing the starting switch to OFF position to stop the engine.

KOMATSU CLOSED CRANKCASE VENTILATION (KCCV)

KCCV is a device to clean the gas discharged from the engine
crankcase and return it to the engine air intake system.

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OPERATION EXPLANATION OF COMPONENTS

NOTICE
• The filter element needs to be replaced every 2000 hours.
• Do not operate the engine without the KCCV filter element or use a filter element other than the Ko-
matsu genuine one.
If this is ignored, the engine sucks oil and foreign material which can cause a trouble.
Always install Komatsu genuine KCCV filter element.
• The filter element cannot be flushed. It is degraded in performance and can cause an engine trou-
ble, even if it is cleaned.
Never reuse the element.

HANDLE UREA SCR SYSTEM WARNING

Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless nitro-
gen and water. By spraying DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3)
and the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.
The Komatsu Urea SCR System continuously monitors its operation conditions and stores information on inap-
propriate operations including malfunctions. The information is used for system diagnostics and also for Induce-
ment required by the authorities on engine systems that use Urea SCR systems. Inducement is intended for the
operator to take prompt actions to maintain and correct inappropriate behaviors of Urea SCR systems by utiliz-
ing visible and audible alerts , and engine power derate in addition. Alerts in Inducement of the Komatsu Urea
SCR System progresses step by step starting from visual indications on the machine monitor and audible
sounds to engine power derate to avoid getting into unsafe conditions.
The Komatsu Urea System also monitors recurrences of abnormalities of the system. Inducement in the recur-
rences is activated when another abnormality occurs within 40 hours after the first abnormality is fixed.
The Komatsu’s Urea is composed of two major systems, which are the DEF system and the SCR catalyst Ass’y.

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EXPLANATION OF COMPONENTS OPERATION

DEF is supplied from DEF system into the exhaust system.

DEF system consist of DEF tank (1), DEF hose (2), DEF pump
(3), and DEF injector (4). SCR Ass’y is indicated by (5).
In the event that indications of potential degradation of nitrogen
oxides conversion efficiency are detected, the active regenera-
tion is triggered to rejuvenate Urea SCR system even if the
amount of soot accumulated in the KDPF has not reached to
the regeneration thresholds.
For details of Aftertreatment Devices Regeneration, see “HAN-
DLE Komatsu Diesel Particulate Filter (KDPF) (3-126)”.

k WARNING
Fill ONLY DEF into DEF tank. Foreign material in the DEF
system or urea deposits caused by evaporation may hin-
der operation of the devices.

NOTICE
• Do not disassemble any devices of the DEF System
other than the filter for change. Do not modify any de-
vices of the DEF System.
• Paint may cause deterioration of the devices. When
painting the surrounding areas, take care not to get
any paint on the injector and the supply pump.
• Always use DEF that conforms to the quality standard.
If any additional additive agents or water is mixed in
DEF and that mixture is used, the devices will not
function properly, and conformance to the exhaust gas
regulations will be lost. In addition, it may cause fail-
ures in the engine system. If DEF out of the standard
is filled or used by mistake, contact your Komatsu dis-
tributor.
About the operation of Urea SCR system
The Urea SCR System automatically starts operating as soon as the engine is started.
Even after the engine starting switch is turned to the OFF position, the devices will still be in operation for sever-
al minutes to purge any DEF in the lines, the injector and the supply pump back to the DEF tank. It does not
indicate any abnormality. When DEF has been returned to the tank, the devices stop.
Do not turn OFF the battery disconnect switch while the devices are still in operation. When the devices com-
plete their shutdown process, the system operating lamp will go out, and the battery disconnect switch may be
disconnected.
About the operation in cold weather
DEF freezes at –11 °C.
Urea SCR system is equipped with a heating system to thaw frozen DEF once it is frozen, for example, during
parking and to prevent DEF from freezing during operation.
In case DEF freezes during parking, once the engine starts running the heating system automatically starts pro-
viding heat to thaw frozen DEF. The pump and the injector start working only after a proper amount of DEF is
thawed. This may be noticed as a delay in the start of functioning of the pump and the injector.
The heating system is also activated automatically during operation to prevent DEF from freezing whenever the
ambient temperature drops below a certain threshold where DEF in the system may freeze. In the event that the
ambient temperature drops further than a temperature where the heating system is capable of maintaining fluidi-
ty of DEF, the DEF system automatically starts purging the remaining DEF back to the tank and stops pumping

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OPERATION EXPLANATION OF COMPONENTS

and injection while heating continues. Once the ambient temperature rises above a temperature where DEF
system becomes functional, it resumes operation automatically.
Short duration of white plume given off from the tail pipe may be visible at and shortly after engine start-up in
cold weather, but this is not malfunction.
Inducement strategy when the DEF tank Level becomes low
When the amount of DEF fluid in the tank goes low, the Inducement strategy will be activated.
If Inducement starts, add DEF to the DEF tank immediately.
The DEF level caution lamp (1) on the monitor lights up, the
audible alert starts, and the Action level is displayed, and In-
ducement strategy is activated. Inducement strategy includes
engine output deration, speed limitation, or other warning ac-
tions intend to prompt the operator to maintain or repair SCR
system. The Inducement strategy progresses in 4 levels from
Warning, Continuous Warning, Low level Inducement and Se-
vere Inducement. The DEF level caution lamp (1) on the ma-
chine monitor will light up, audible alert will start, then Action
level will be displayed on the machine monitor, and engine
power will be derated in steps.
In Action Level “L03 (Low level Inducement)” and “L04 (Severe Inducement)” engine power will be derated.
When Action Level “03” or “04” is displayed, move the machine to a safe place and add DEF.
The content of the warning can be checked on the “SCR Information” screen of the user menu.
Perform the following procedure.
Press the menu switch on the standard screen to display the
“SCR Information” screen of the user menu.
After a lapse of 3 seconds to stop the machine, “SCR Informa-
tion” screen is displayed.

“SCR Information” screen displays the DEF level caution lamp

(1), the DEF level gauge (2), information on the Urea SCR Sys-
tem condition (3), and the current status of Inducement (4).
If Inducement starts, stop the machine in a safe place and add
DEF.

• Warning:
2 gradations of the DEF level gauge light up in the red
range.
The DEF level caution lamp (1) lights up in red.
No audible alert.
No Action level is displayed.
Press the menu switch to display the “SCR Information”
screen.

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EXPLANATION OF COMPONENTS OPERATION

Inducement status (4): “1 DEF low level warning appears.”

Add DEF to the DEF tank immediately.

• Continuous Warning:
The audible alert sounds in “Intermittent alarm”.
2 gradations of the DEF level gauge light up in the red
range.
DEF level caution lamp (1) lights up in red.
No Action level is displayed.
Press the menu switch to display the “SCR Information”
screen.

Inducement status (4): “2 Without treatment, engine power

will be derated.”
Add DEF to the DEF tank immediately.

• Low level Inducement:

The audible alert sounds in “Intermittent alarm”.
1 gradation of the DEF level gauge light up in red.
The DEF level caution lamp (1) lights up in red.
Action Level “L03” is displayed in red (5).
Press the menu switch to display the “SCR Information”
screen.

Inducement status (4): “3 Engine power is under deration.”

Add DEF to the DEF tank immediately.

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OPERATION EXPLANATION OF COMPONENTS

• Severe Inducement:
The audible alert sounds in “Continuous alarm”.
No gradation of the DEF level gauge lights up .
The DEF level caution lamp (1) lights up in red.
The Action level “L04” is displayed in red (5).
Press the menu switch to display the “SCR Information”
screen.
When all gradations of the DEF level gauge go off, DEF re-
filling amount is approximately 14 ℓ to fill up the DEF tank.

Inducement status (4): “4 Engine power is under heavy de-

ration.”

Engine power can be restored temporarily from power derate. This engine power restoration works only
when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of
the “Low level Inducement”. The operator can restore engine power through the machine monitor. For the
engine power restoration procedure, refer to the section of “Temporary Restoration from Inducement” in this
manual. Once in “Severe Inducement” and it becomes necessary to restore engine power, use the engine
power restoration function to move the machine to a safe place and add DEF.
Inducement strategy when abnormalities are detected in the Urea SCR System
devices (Except abnormalities in the KDPF and the EGR system)
If any abnormality is detected in the DEF quality or in the Urea SCR system, the Inducement strategy is activa-
ted.
The inducement strategy progresses in 4 levels, “Warning”,
“Continuous Warning”, “Low level Inducement” and “Severe In-
ducement”. The Inducement strategy includes visual alert by
the DEF system caution lamp (1), and Action Level displayed
on the machine monitor (2), and the audible alert by a buzzer
and stepwise engine power derates. Engine power deration
starts with Action Level “L03 (Low level Inducement)” and ad-
vances to further deration when “L04 (Severe Inducement)” is
displayed. If “L03” is displayed, move the machine to a safe
place and contact your Komatsu distributor.
The content of the warning can be checked on the “SCR Infor-
mation” screen of the user menu.
Perform the following procedure.
Press the menu switch on the standard screen to display the
“SCR Information” screen of the user menu.
After a lapse of 3 seconds to stop the machine, “SCR Informa-
tion” screen is displayed.

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EXPLANATION OF COMPONENTS OPERATION

“SCR Information” screen displays remaining time to the next

Inducement status in the column (5), and information on the
Urea SCR System condition (3), and the current status of In-
ducement (4).

• Warning:
No audible alert.
The DEF system caution lamp (1) lights up in yellow.
Note: Action Level “L01” once shows up in yellow on the
machine monitor (2) for two seconds and goes out.
Press the menu switch to display the “SCR Information”
screen.

“SCR Information” screen message (4): “1 Please inspect

and maintain SCR system.”
Move the machine to the safe place and contact your Ko-
matsu Distributor.
If operation continues for 5 hour after “Warning” started
without taking any actions instructed by the Action Level
table, Inducement advances to “Continuous Warning”.

• Continuous Warning:
The audible alert sounds in “Intermittent alarm”.
The DEF system caution lamp (1) lights up in yellow.
If operation continues for 5 hour after “Warning” started
without taking any actions instructed by the Action Level
table, Inducement advances to “Continuous Warning”.
Press the menu switch to display the “SCR Information”
screen.

“SCR Information” screen message (4): “2 Without treat-

ment, engine power will be derated.”
Move the machine to the safe place and contact your Ko-
matsu Distributor.
The duration of “Continuous Warning” is 5 hours. The re-
maining time (Hours and Minutes) to “Low level Induce-
ment” is displayed in the column (5) of the “SCR Informa-
tion” screen.
In “Low level Inducement”, engine power will be derated.

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OPERATION EXPLANATION OF COMPONENTS

• Low level Inducement:

The audible alert sounds in “Intermittent alarm”.
The DEF system caution lamp (1) lights up in red.
Action level “L03” lights up in red at action level display (2)
and stays on.
Press the menu switch to display the “SCR Information”
screen.

“SCR Information” screen message (4): “3 Engine power is

under deration.”
Due to the engine power deration, capability of the ma-
chine will be limited.
Move the machine to the safe place and contact your Ko-
matsu Distributor.
The duration of “Low level Inducement” is 10 hours. The
remaining time (Hours and Minutes) to “Severe Induce-
ment” is displayed in the column (5) of the “SCR Informa-
tion” screen.
In “Severe Inducement”, engine power will be derated fur-
ther.
• Severe Inducement:
The audible alert sounds in “Continuous alarm”.
The DEF system caution lamp (1) lights up in red.
Action level “L04” lights up in red (2).
Press the menu switch to display the “SCR Information”
screen.

“SCR Information” screen message (4): “4 Engine power is

under heavy deration.”
Due to the further deration of engine power, capability the
machine will be limited further.
“Severe Inducement” is the final status of Inducement.
Unless all the “SCR system” abnormalities are corrected,
engine performance will be kept derated.

Engine power can be restored temporarily from power derate. If Inducement advances to “Severe Induce-
ment” and it becomes necessary to restore engine power, use the engine power restoration function to
move the machine to a safe place and contact your Komatsu distributor. This engine power restoration
works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power
deration of “Low level Inducement”. The operator can restore engine power through the machine monitor.
For the engine power restoration procedure, refer to the section of “Temporary Restoration from Induce-
ment” in this manual.
Inducement strategy when abnormality is found in the KDPF System by the
Urea SCR system
If any abnormality is detected in the KDPF System through the Urea SCR system, the Inducement strategy is
activated.

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EXPLANATION OF COMPONENTS OPERATION

The inducement strategy progresses in 4 levels, “Warning”,

“Continuous Warning”, “Low level Inducement”, and “Severe In-
ducement”. The Inducement strategy includes visual alert by
the KDPF System caution lamp (1), DEF system caution lamp
(2), and Action Level displayed on the machine monitor (3), au-
dible alert by a buzzer and stepwise engine power derates. En-
gine power deration starts with Action Level “L03 (Warning,
Continuous Warning and Low level Inducement)” and advances
to further deration when “L04 (Severe Inducement)” is dis-
played. Once the system advances to “Severe Inducement”,
the engine power will be further derated. If “L03” is displayed,
move the machine to a safe place and contact your Komatsu
distributor.
The content of the warning can be checked on the “SCR Information” screen of the user menu.
Perform the following procedure.
Press the menu switch on the standard screen to display the
“SCR Information” screen of the user menu.
After a lapse of 3 seconds to stop the machine, “SCR Informa-
tion” screen is displayed.

“SCR Information” screen displays remaining time to the next

Inducement status in the column (6), and information on the
Urea SCR System condition (4), and the current status of In-
ducement (5).

• Warning:
The audible alert sounds in “Intermittent alarm”.
The KDPF system caution lamp (1) lights up in red.
The action level “L03” lights up in red at action level dis-
play (3).
Press the menu switch to display the “SCR Information”
screen.

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OPERATION EXPLANATION OF COMPONENTS

“SCR Information” screen message (5): “1 Please inspect

and maintain SCR system.”
Engine power is derated.
Move the machine to the safe place and contact your Ko-
matsu Distributor.
If operation continues for 5 hour after “Warning” started
without taking any actions instructed by the Action Level
table, Inducement advances to “Continuous Warning”.

• Continuous Warning:
The audible alert sounds in “Intermittent alarm”.
The KDPF system caution lamp (1) lights up in red.
The DEF system caution lamp (2) lights up in yellow.
The action level “L03” lights up in red at action level dis-
play (3).
Press the menu switch to display the “SCR Information”
screen.

“SCR Information” screen message (5): “2 Without treat-

ment, engine power will be derated.”
Move the machine to the safe place and contact your Ko-
matsu Distributor.
The duration time of “Continuous Warning” is 5 hour. The
remaining time (Hours and Minutes) to “Low level Induce-
ment” is displayed in the column (6) of “SCR Information”
screen.
In “Low level Inducement”, engine power will be derated.

• Low level Inducement:

The audible alert sounds in “Intermittent alarm”.
The KDPF system caution lamp (1) lights up in red.
The DEF system caution lamp (2) lights up in red.
The action level “L03” lights up in red at action level dis-
play (3).
Press the menu switch to display the “SCR Information”
screen.

“SCR Information” screen message (5): “3 Engine power is

under deration.”
Due to the reduction of engine power, the machine normal
operation will be limited.
The duration time of “Low level Inducement” is 10 hour.
The remaining time (Minutes) to “Severe Inducement” is
displayed in the column (6) of “SCR Information” screen.
In “Severe Inducement”, engine power will be derated fur-
ther.
Move the machine to the safe place and contact your Ko-
matsu Distributor.

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EXPLANATION OF COMPONENTS OPERATION

• Severe Inducement:
The audible alert sounds in “Continuous alarm”.
The KDPF system caution lamp (1) lights up in red.
The DEF system caution lamp (2) lights up in red.
Action level “L04” lights up in red at action level display (3).
Press the menu switch to display the “SCR Information”
screen.

“SCR Information” screen message (5): “4 Engine power is

under heavy deration.”
Due to the further deration of engine power, capability the
machine will be limited further.
If the restoration of the KDPF system abnormality is not
performed, engine power will kept be derated.

Engine power can be restored temporarily from power derate. This engine power restoration works only
when the Inducement status is “Severe Inducement” and relieves back temporarily from power derate. This
engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back
temporarily to the power deration of “Low level Inducement”. The operator can restore engine power
through the machine monitor. For the engine power restoration procedure, refer to the section of “Tempora-
ry Restoration from Inducement” in this manual. If Inducement advances to “Severe Inducement” and it be-
comes necessary to restore engine power, use the engine power restoration function to move the machine
to a safe place and contact your Komatsu distributor.
Inducement strategy when abnormality is found in the EGR Valve System by the
Urea SCR system
If any abnormality is detected in the EGR Valve System through the Urea SCR system, the Inducement strategy
is activated.
The inducement strategy progresses in 4 levels, “Warning”,
“Continuous Warning”, “Low level Inducement”, and “Severe In-
ducement”. The Inducement strategy includes visual alert by
the Engine system caution lamp (1), DEF system caution lamp
(2), and Action Level displayed on the machine monitor (3), au-
dible alert by a buzzer and stepwise engine power derates. En-
gine power deration starts with Action Level “L03 (Warning,
Continuous Warning and Low level Inducement)” and advances
to further deration when “L04 (Severe Inducement)” is dis-
played. Once the system advances to “Severe Inducement”,
the engine power will be further derated. If “L03” is displayed,
move the machine to a safe place and contact your Komatsu
distributor.
The content of the warning can be checked on the “SCR Information” screen of the user menu.

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OPERATION EXPLANATION OF COMPONENTS

Perform the following procedure.

Press the menu switch to display the “SCR Information” screen
of the user menu.
After a lapse of 3 seconds to stop the machine, “SCR Informa-
tion” screen is displayed.

“SCR Information” screen displays remaining time to the next

Inducement status in the column (6), and information on the
Urea SCR System condition (4), and the current status of In-
ducement (5).

• Warning:
The audible alert sounds in “Intermittent alarm”.
The Engine system caution lamp (1) lights up in red.
The action level “L03” lights up in red at action level dis-
play (3).
Press the menu switch to display the “SCR Information”
screen.

“SCR Information” screen message (5): “1 Please inspect

and maintain SCR system.”
Engine power is derated.
Move the machine to the safe place and contact your Ko-
matsu Distributor.
If operation continues for 5 hour after “Warning” started
without taking any actions instructed by the Action Level
table, Inducement advances to “Continuous Warning”.

• Continuous Warning:
The audible alert sounds in “Intermittent alarm”.
The Engine system caution lamp (1) lights up in red.
The DEF system caution lamp (2) lights up in yellow.
The action level “L03” lights up in red at action level dis-
play (3).
Press the menu switch to display the “SCR Information”
screen.

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EXPLANATION OF COMPONENTS OPERATION

“SCR Information” screen message (5): “2 Without treat-

ment, engine power will be derated.”
Move the machine to the safe place and contact your Ko-
matsu Distributor.
The duration time of “Continuous Warning” is 5 hour. The
remaining time (Hours and Minutes) to “Low level Induce-
ment” is displayed in the column (6) of “SCR Information”
screen.
In “Low level Inducement”, engine power will be derated.

• Low level Inducement:

The audible alert sounds in “Intermittent alarm”.
The Engine system caution lamp (1) lights up in red.
The DEF system caution lamp (2) lights up in red.
The action level “L03” lights up in red at action level dis-
play (3).
Press the menu switch to display the “SCR Information”
screen.

“SCR Information” screen message (5): “3 Engine power is

under deration.”
Due to the reduction of engine power, the machine normal
operation will be limited.
The duration time of “Low level Inducement” is 10 hour.
The remaining time (Hours and Minutes) to “Severe In-
ducement” is displayed in the column (6) of “SCR Informa-
tion” screen.
In “Severe Inducement”, engine power will be derated fur-
ther.
Move the machine to the safe place and contact your Ko-
matsu Distributor.
• Severe Inducement:
The audible alert sounds in “Non-stopping alarm”.
The Engine system caution lamp (1) lights up in red.
The DEF system caution lamp (2) lights up in red.
Action level “L04” lights up in red at action level display (3).
Press the menu switch to display the “SCR Information”
screen.

“SCR Information” screen message (5): “4 Engine power is

under heavy deration.”
Due to the further deration of engine power, capability the
machine will be limited further.
If the restoration of the EGR valve system abnormality is
not performed, engine power will kept be derated.

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OPERATION EXPLANATION OF COMPONENTS

Engine power can be restored temporarily from power derate. This engine power restoration works only
when the Inducement status is “Severe Inducement” and relieves back temporarily from power derate. This
engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back
temporarily to the power deration of “Low level Inducement”. The operator can restore engine power
through the machine monitor. For the engine power restoration procedure, refer to the section of “Tempora-
ry Restoration from Inducement” in this manual. If Inducement advances to “Severe Inducement” and it be-
comes necessary to restore engine power, use the engine power restoration function to move the machine
to a safe place and contact your Komatsu distributor.
Temporary Restoration from Inducement
Temporary Restoration from Inducement is the one of the Inducement strategies allowed to be included in Urea
SCR systems.
In case the Urea SCR system advances to “Severe Inducement”, engine power is derated heavily. This may
cause difficulties of moving the machine to a safe place for adding DEF or troubleshooting and correcting abnor-
malities of the Urea SCR system. For temporary remedies from these difficulties the operator can restore engine
power for a short time to the deration of “Low level Inducement” through the machine monitor. Note that “Tempo-
rary Restoration from Inducement” does not regain full engine power.
“Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe In-
ducement”. The maximum duration is limited to 30 minutes in each restoration operation, and only 3 operations
are allowed unless all the abnormalities of the Urea SCR system are corrected.
If the system advances to “Severe Inducement”, utilize “Temporary Restoration from Inducement” immediately.
Procedure to activate “Temporary Restoration from Inducement”.
1. Press the menu switch (1) to display the “SCR Information”
screen when the Standard screen is on, only when the
Urea SCR system is in “Severe Inducement”.

2. Press the enter switch (2) to display the menu windows

popping up in the bottom half of the “SCR Information”.
The menu windows popping up in the bottom half of the
“SCR Information” screen alternate every 15 seconds as
shown in the graphics A and B.

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EXPLANATION OF COMPONENTS OPERATION

3. Press the enter switch (2) while the pop-up menu screen B
is displayed.
The “Engine power Recovery” window will be displayed.
If the enter switch (2) is not pressed for 30 seconds,
“Standard Screen” will be displayed, and start again by
pressing the menu switch (1).
The remaining number of operations of Temporary Resto-
ration from inducement is displayed in the column (3) of
the pop-up menu window B.

4. Press the enter switch (2) while the “Engine power Recov-
ery” window is displayed.
Temporary Restoration from Inducement is activated and
engine power deration is relieved to the deration of “Low
level Inducement” for the maximum of 30 minutes.

The remaining time (minutes/seconds) of “Temporary Re-

storation from Inducement” is displayed in the column (4)
on the “SCR Information” screen.

If it is decided NOT to activate “Temporary Restoration from Inducement” after having progressed to the “Engine
Power Recovery” window, follow the steps explained in this section.
To deactivate “Temporary Restoration from Inducement” function.

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OPERATION EXPLANATION OF COMPONENTS

1. Press the return switch (5) while the “Engine Power Re-
covery” window is displayed.
This procedure is split from procedure 4 in “Temporary Re-
storation from Inducement”.

“SCR Information” screen is displayed.

2. Move the machine to display the to display “Standard

Screen”.
“Temporary Restoration from Inducement” is deactivated.

Inducement Strategy for abnormalities recurrences within 40 hours

The Urea SCR system continuously monitors its operation conditions and stores information on inappropriate
operations including malfunctions. The stored information is utilized to monitor recurrences of abnormalities,
“Abnormality Recurrence Counter”. “Abnormality Recurrence Counter” is required by the authorities. The recur-
rence monitoring spans 40 hours and it monitors the abnormalities that trigger Inducement other than the
amount of DEF in the tank.
If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were corrected,
regardless of the level of the previous Inducement and whether the new abnormality/abnormalities is the same
as the previous ones or not, it is judged as a recurrence.
If a recurrence occurs, “Severe Inducement” will be activated.
Inducement in the recurrence resumes counting time at the time when the previous abnormalities were correc-
ted if the previous Inducement is in “ Warning” or “Continuous Warning” or “Low level Inducement”. The alerts
resume the previous Inducement.
If this occurs, utilize “Temporary Restoration from Inducement” and move the machine to a safe place, and con-
tact your Komatsu distributor.
The maximum duration of power restoration is 30 minutes and 3 operations are allowed.
To activate “Temporary Restoration from Inducement”, refer to the “Temporary Restoration from Inducement”
section in this manual.

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EXPLANATION OF COMPONENTS OPERATION

DEF FILTER
DEF filter is an filter element to clean DEF sucked from the
DEF tank by DEF pump, and to supply it to DEF injector.
NOTICE
• The DEF filter element needs to be replaced every
2000 hours. For details of the replacement procedure,
see “METHOD FOR REPLACING DEF FILTER (4-77)”.
• If the machine is operated without DEF filter attached,
or with the filter other than Komatsu genuine parts,
foreign materials may enter into DEF pump and DEF
injector which will cause failure of the machine. Never
operate the machine without DEF filter attached, nor
use the filter other than Komatsu genuine parts.
• DEF filter cannot be flushed. Flushing or regenerating
of it will degrade the performance of DEF filter, and will
contaminate DEF pump and DEF injector which will
cause the failure of the machine. Never reuse the DEF
filter.

KOMTRAX
k WARNING
• Never disassemble, repair, modify, or move the wireless communication terminal, antenna, or ca-
bles. This may cause failure or fire on the wireless equipment or the machine itself.
• Near the blasting jobsite, there may be a danger of unexpected explosion due to use of the wireless
equipment and resulting serious personal injury or death.
If you have to operate the machine within 12 m from the remote-controlled blasting device, the pow-
er supply cable of the wireless communication device must be disconnected in advance.

KOMTRAX is a vehicle management system that remotely manages the machines equipped with the KOM-
TRAX device by using satellite communication or portable radio communication.
The GPS (Global Positioning System), receiver, and communication system are equipped in the vehicle man-
agement system.
The machine information such as the machine maintenance, maintenance management, operating situation
management, and machine location management is gathered from the inside network of the machine. It can be
useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma-
chine information for supply of service to the customers, improvement of our products and service, etc.
The type of information which is sent from the machine may vary depending on the machine. For the radio sta-
tion establishment of KOMTRAX, consult your Komatsu distributor.

POWER SUPPLY FOR KOMTRAX

• Even when the starting switch is in OFF position, KOMTRAX system consumes a small amount of electric
power.
It is recommended to start the engine periodically to charge the battery. When storing the machine for a
long period, see “PRECAUTIONS FOR LONG-TERM STORAGE (3-231)”.
• When using the battery disconnect switch, turn the starting switch to OFF position and, after checking that
the system operating lamp is not lit, set the battery disconnect switch key to OFF position and pull it out.
When the battery disconnect switch is turned to OFF position, it prevents the battery power from being con-
sumed, but the functions of KOMTRAX stop at the same time.
For operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-119)”.
• If the power supply cable of KOMTRAX system device has to be disconnected, contact your Komatsu dis-
tributor.

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MACHINE OPERATIONS AND CONTROLS

CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE
METHOD FOR WALK-AROUND CHECK
Before starting the engine, walk around the machine and look at the underside of chassis for anything unusual
like loose bolts and nuts, damage of each part, or leakage of oil, fuel, or coolant. Also check the condition of the
work equipment and the hydraulic system. Also check for loose wiring, play, and accumulation of dust in places
that reach high temperatures.

k WARNING
Any combustible materials accumulated around the exhaust pipe, aftertreatment devices, turbocharger,
or other high temperature engine parts or the battery, and leakage of fuel or oil will cause the machine
to catch fire.
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor.

If the machine is inclining, make it level before checking.

Always perform the following inspections and cleaning every day before starting engine for the day's work.
1. Check for damage, wear, play in work equipment, cylinders, linkage, and hoses.
Check for cracks, excessive wear, play in work equipment, cylinders, linkage, and hoses. If any problem is
found, repair it.
2. Remove dirt and debris from the center hinge portion.
Check for the deposit such as dirt and debris. If any of them is found, remove it.
3. Remove dirt and debris from around the engine, battery, and radiator.
Check for dirt accumulated around the engine and radiator. Also check for combustible material (dry leaves,
twigs, etc.) around the battery, aftertreatment devices, turbocharger, or other high temperature engine parts.
If any dirt or combustible materials are found, remove them.
4. Check around the engine for leakage of coolant, oil, and exhaust gas.
Check the engine for leakage of oil and exhaust gas, and check the cooling system for coolant leakage. If
any problem is found, repair it.
5. Check the fuel line for leakage.
Check for leakage of fuel or damage to the hoses and tubes. If any problem is found, repair it.
6. Remove dirt and check DEF line for leakage.
Check for dirt accumulated around the DEF tank and clean blue DEF tank filler cap and surrounding area.
Check DEF tank, pump, injector, and hoses and their connections for leakage. If any problem is found, ask
your Komatsu distributor for repair.
7. Remove dirt from around the aftertreatment devices.
Check for dirt and combustible materials (dry leaves, twigs, etc.) accumulated around the aftertreatment de-
vices. If any dirt or combustible materials are found, remove them.
8. Check around the aftertreatment devices for exhaust gas leakage.
Check the pipe connecting the turbocharger to the aftertreatment devices and also connections of the after-
treatment devices for leakage of exhaust gas (and deposition of soot).
If any problem is found, ask your Komatsu distributor for repair.
9. Check KCCV piping for gas leakage and oil leakage.
Check the pipes (3 pieces) between the KCCV filter, turbocharger, oil pan, and cylinder head for oozing oil.
If any problem is found, ask your Komatsu distributor for repair.
10. Check around SCR for exhaust gas leakage.
Check the pipe between the KDPF and SCR and also the SCR connections for leakage of exhaust gas
(and urea deposit). If any problem is found, ask your Komatsu distributor for repair.

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11. Check the HST piping, transfer case, axle, hydraulic tank, hoses, and joints for oil leakage.
Check for oil leakage. If any problem is found, repair the place where the oil is leaking.
12. Check brake line for oil leakage.
Check for leakage of oil or damage to the hoses and tubes. If any problem is found, repair it.
13. Check the tires, wheels, and wheel hub bolts and nuts for damaged and wear, and check the wheel hub
bolts and nuts for looseness.
Check for cracks or peeling of the tires and for cracks or wear of the wheels (side ring, rim base, lock ring).
Tighten any loose wheel hub bolts or nuts. If any problem is found, repair or replace the part.
If any valve cap is missing, install a new one.
14. Check the handrails and steps for damages and check the bolts for looseness.
If any damage is found, repair it. Tighten any loose bolts.
15. Check the gauges and monitor for problem.
Check for problem in the gauges and monitor in the operator's cab. If any problem is found, replace the
part. Clean off any dirt on the surface.
REMARK
When cleaning the stains deposited on the monitor surface such as dusts, brush them off using a clean,
soft and dry cloth.
For sticky dirt such as oil, remove it with glass cleaner for family use on the market (weakly acid to weakly
alkaline, containing no abrasive), and then finish-wipe with a clean, soft, and dry cloth.
16. Check the rearview mirrors.
Check the rear view mirror for trouble. If it is damaged, repair it. Clean the surface of the mirror and adjust
the angle so that the area at the rear can be seen from the operator's seat.
17. Check the air cleaner mounting bolts for looseness.
Check for loose mounting bolts. If any loose bolt is found, retighten it.
18. Check battery terminals for looseness.
If any loose terminal is found, retighten it.
Tightening torque of portion A: 9.8 to 11.8 Nm {1.0 to
1.2 kgm}
Tightening torque of portion B: 11.8 to 19.6 Nm {1.2 to
2.0 kgm}

19. Check the seat belt and mounting hardware.

k WARNING
Even if no problem can be seen on the appearance of
the seat belt, replace it in accordance with the follow-
ing schedule whichever date comes sooner.
5 years after the date of seat belt manufacture, or ev-
ery 3 years after the start of actual usage.

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REMARK
The date indicated on the seat belt is the manufactured
date. It is the start of the 5-year period.
The manufactured date of the seat belt is printed on the la-
bel indicated by the arrow in the figure.
Check for any loose bolts of the hardware mounting the
equipment to the machine. Retighten any loose bolts.
Tightening torque: 39.2 ± 2 Nm {4.0 ± 0.2 kgm}
If the seat belt is scratched or frayed, if any fittings are bro-
ken or deformed, replace the seat belt with a new one.
20. Clean cab windows.
Clean the cab windows to secure visibility during operation.
Cleaning from the top of the fender or platform is very dangerous.
Clean with a mop etc. from the ground.
21. Check the tires.

k WARNING
If worn or damaged tires are used, they may burst and
cause serious injury or death.
To ensure safety, do not use the following tires.
Wear:
• Tires with a tread grooves of less than 15 % of that
of a new tire
• Tires with extreme uneven wear or with stepped-
type wear
Damage:
• Tires with damage that has reached cords (1), or
with cracks in the rubber
• Tire with cut or broken cords (1)
• When tires are peeled (separated)
• Tires with damaged bead (2)
• Leaking or improperly repaired tubeless tires
• Deteriorated, deformed or abnormally damaged
tires, which do not seem usable.

22. Check the wheel rims.

k WARNING
Check that the rims (wheels) and rings are free from deformation, damage caused by corrosion and
cracks.
In particular, check the side rings, lock rings and rim flanges thoroughly.
If any problem is found, replace the part.

23. Check the rearview monitor.

Check the rearview monitor for problem. If it is failed, ask your Komatsu distributor for repair.

METHOD FOR CHECKING BEFORE STARTING

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

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METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDI-

MENT
k WARNING
• Immediately after the engine is stopped, all of parts are still very hot. Avoid draining water or re-
moving the transparent cup.
Wait for all parts to cool down before starting the work.
• When the engine has run, high-pressure is generated in the engine fuel piping. When draining the
water or removing the transparent cup, wait for at least 30 seconds after stopping the engine to let
the internal pressure go down before starting the work.
• Do not bring any open flame close.

1. Open the engine side cover (1) on the right side of the machine.
Water separator (2) is integrated with the fuel prefilter and
located in the lower part.

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OPERATION MACHINE OPERATIONS AND CONTROLS

2. Check for water and sediment.

It is possible to judge the water level and amount of sedi-
ment by looking through transparent cup (4).
NOTICE
• If the water accumulated in transparent cup (4)
freezes, the water separator caution lamp (6) may
not light up. After the engine is started, as the
temperature around fuel prefilter increases, the
frozen water melts and the water separator cau-
tion lamp (6) may suddenly light up. In cold sea-
son, even if the water separator caution lamp (6) is
not lit, drain the water frequently.
• If the water inside transparent cup (4) freezes, wait
until the frozen water has melted completely, then
follow the procedures to drain the water.
3. Place a container under drain hose (5) to receive the wa-
ter.
4. Loosen plug (3) and drain the water.
5. When fuel starts to be drained from drain hose (5), tighten
plug (3) immediately to stop draining.
Tightening torque: 0.2 to 0.45 Nm {0.02 to 0.046 kgm}
REMARK
• On this machine, a sensor is installed to detect if water accumulates in transparent cup (4).
When the water separator caution lamp (6) lights up in red on the machine monitor, it indicates that
water is accumulated in transparent cup (4).
In this case as well, use the procedure above to drain the water.
• When only the water separator caution lamp lights up, it lights up at position (6).
If other caution lamps also light up at the same time, the water separator caution lamp lights up at a
different position.
REMARK
If drain plug (3) is hard to turn, apply grease to O-ring (7) of plug (3) according to the following procedure.
1) Place a container under the drain hose (5) to catch the
fuel.
2) Loosen plug (3) and drain all the fuel and sediment
through drain hose (5).
3) Check that nothing more comes out from drain hose
(5), then remove plug (3).
4) Apply a suitable amount of grease to O-ring (7). At this
time, take care that grease will not stick to water drain
port (a) and threaded portion of the plug.
5) Tighten plug (3) by hand until it stops.
6) Remove the container to catch the drained fuel.
• If the transparent cup (4) is so dirty that the inside cannot be seen, clean the transparent cup (4)
when replacing the filter.
• In the case that the plug (3) has been removed during the cleaning work, apply grease to O-ring
(7) and tighten with your fingers until it stops.

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MACHINE OPERATIONS AND CONTROLS OPERATION

METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT

k WARNING
• Do not open the radiator cap unless it is necessary. When checking the coolant level, check it with
the reservoir tank when the engine is cold.
• Immediately after the engine is stopped, the coolant is hot. Also, the pressure is accumulated in the
radiator. You may get burn injury if you remove the cap in this state. Wait for the temperature to go
down, and then turn the cap slowly to release the pressure.

k CAUTION
When refilling with coolant, support your body securely by using the steps and handrails provided.

1. Open the engine side cover (1) on the left side of the ma-
chine.

2. Check the reservoir tank (2).

Check that the coolant level is between FULL and LOW
marks of the reservoir tank (2).
3. If the coolant is insufficient, add the coolant to FULL level
through the filler port of the reservoir tank (2).
4. Tighten the cap securely after the refilling.
If reservoir tank (2) is empty, leakage of coolant is suspect-
ed. After checking, repair any abnormality immediately.
If no abnormality is found, check the level of the coolant in
the radiator. If it is low, add coolant of the same density in
radiator according to the coolant density table in “METH-
OD FOR USING FUEL, COOLANT AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE”, and then
add coolant to the reservoir tank.
If coolant is added more than usual, check for the leakage.
Check that there is no abnormality such as oil mixed into
the coolant.

METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL
k WARNING
Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.

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OPERATION MACHINE OPERATIONS AND CONTROLS

1. Open the engine side cover (1) on the right side of the ma-
chine.

2. Pull out the dipstick (G) and wipe the oil off with a cloth.
3. Fully insert the dipstick (G) into the dipstick pipe, then pull
it out.
If the oil level is between marks H and L, it is correct.
If the oil level is below L mark, add oil through oil filler port
(F).
4. If the oil level is higher than H mark, drain the excessive oil
from the drain plug (P).
5. Check the oil level again.
6. If the oil level is correct, tighten the oil filler cap (F) secure-
ly.
7. Close the engine side cover (1).
REMARK
• Wait for at least 15 minutes after stopping the engine
after the engine has been operated, and check the oil
level.
• If the machine is inclining, make it level before check-
ing.
• When the ambient temperature is low, water or emul-
sified matter may stick to the dipstick, fuel filler cap,
etc. or the drained oil may be milky white because of
water vapor in the blowby gas. However, if the coolant
level is normal, it is not a problem.
• If the coolant level is low, add coolant.

METHOD FOR CHECKING DUST INDICATOR

1. Open the engine side cover (1) on the right side of the ma-
chine.

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MACHINE OPERATIONS AND CONTROLS OPERATION

2. Check that the yellow piston shown in dust indicator (2)

display does not enter the red (7.5 kPa {0.08 kg/cm2}) po-
sition.
If the yellow piston has entered the red (7.5 kPa
{0.08 kg/cm2}) position, clean or replace the air cleaner el-
ement immediately.
For the cleaning method of the element, see “METHOD
FOR CHECKING, CLEANING AND REPLACING AIR
CLEANER”.

3. After cleaning and replacing, push the button of the dust

indicator (2).
The yellow piston returns.
In an environment where the rubber is deteriorated or the
surface is damaged easily (in the direct sunlight, sandy
district, etc.), replace it before reading becomes difficult
because of dirt.

METHOD FOR CHECKING ELECTRIC WIRING

k CAUTION
• If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring,
promptly ask your Komatsu distributor to locate the cause of it and to perform the repair.
• Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged
with dirt or dust, wash the battery cap with water to clear the vent hole.

NOTICE
In particular, inspect the wiring of “battery”, “starting motor”, and “alternator” with care.
Perform the following inspection.
• Perform inspection to confirm that the fuses have no defect and their capacity is proper.
• Perform inspection to confirm that there is no disconnection or trace of short-circuiting in the electric wiring
and no damage to the coating.
• Perform inspection to confirm that there is no loose terminals, and tighten any loose parts if found.
• Always check if there is any accumulation of combustible material around the battery, and remove such
combustible material.

METHOD FOR CHECKING FUEL LEVEL, ADDING FUEL

k WARNING
Do not add any more fuel after the fuel filler gun has automatically stopped when refilling with fuel. If
fuel is excessively added, fuel may expand and flow out when ambient temperature increased. It is dan-
gerous.
Also, it may cause fire. Wipe up the spilled fuel completely.
Fuel is highly flammable, and it is dangerous. Never bring any open flame near fuel.

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NOTICE
When restarting the engine that has stopped because of running out of fuel, all air must be sufficiently
bled from the circuit.
For the method of bleeding air, see “METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE (4-55)”.
Take care not to cause engine stall because of running out of fuel.
When fuel is used up, you can cut the air bleeding time by filling up the fuel tank with fuel.
1. Turn the starting switch to ON position (B).

2. Check the fuel level with fuel gauge (G).

3. After checking, return the starting switch to OFF position
(A).

4. Open the rear grill (1), and add fuel through the filler port
(F) to fill up the fuel tank if the fuel level is low.
Once the tank is filled up, do not try to supply additional
fuel.
For the cap opening and closing procedure, see “METH-
OD FOR OPENING AND CLOSING FUEL FILLER PORT
CAP (3-209)”.
5. After adding, tighten the fuel filler cap securely.
Fuel tank capacity: 245 ℓ

METHOD FOR CHECKING DEF LEVEL AND ADDING DEF

k WARNING
• Do not put fluid other than DEF into DEF tank.
• When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face
away from the filler port.
• Foreign materials in the DEF system or urea deposits caused by precipitation of urea may hinder
operation of the devices. Before removing the filler cap, wipe off the dirt from around the filler port.
Before inserting the filler nozzle into the filler port, wipe off dirt from it.
• If DEF is spilled, immediately wipe and wash the area with water. If spilled DEF is left unattended
and the area is not washed and cleaned, it can cause corrosion to the contaminated area and emit
toxic gas.

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NOTICE
• Do not add DEF more than line F of sight gauge (5). DEF may leak through the breather. When the
ambient temperature is low and DEF may freeze, do not add it more than line (9) of sight gauge (5).
Be careful of the DEF level when performing operations on a slope or traveling on a rough ground.
When the remaining DEF level is low, if DEF pump sucks air or if DEF level suddenly lowers causing
a drop of DEF level to the warning level, the engine power may be derated.
• If DEF is stored in unspecified container, foreign material may mix in it and toxic gas or corrosive
substance may be produced by chemical reactions. When adding DEF, do not transfer it to another
container.
• Do not use a funnel when to add DEF. The strainer may be broken.
• When using a portable DEF refill container, use up DEF each time. If any of DEF is left, remove for-
eign material, if there is any.
• Do not wash the adding nozzle in city water. Minerals may clog the devices.
• Do not dilute DEF with water.
• If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution
lamp lights up and the audible alert sounds to warn the abnormality. In this case, ask your Komatsu
distributor for draining of the wrong fluid and for inspection. DEF injector and/or DEF pump may
need to be replaced.
1. Turn the starting switch to ON position (B).

2. Check the DEF level gauge (1) on the machine monitor.

3. After checking, turn the starting switch back to OFF posi-

tion (A).

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4. Set the frame lock bar (2) to LOCK position (L).

5. Open up cover (3) at the right side of the machine, clean

blue DEF tank filler cap (4) and surrounding area.

6. Turn the cap (4) counterclockwise.

The caps of DEF tanks are blue, as required by emission
regulations.
7. By sight gauge (5), add DEF through the filler port until
float (6) reaches line F (7).
Line (8) in the sight gauge indicates approximately 5 ℓ be-
low line F, and line (10) indicates approximately 10 ℓ.
Line (9) is the max adding line when DEF may freeze in
cold weather.

8. After adding, align claw (11) of the cap with groove (12) of
the filler port and close the cap securely by turning it clock-
wise by 90 °.

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MACHINE OPERATIONS AND CONTROLS OPERATION

9. Set the frame lock bar (2) to FREE position (F).

REMARK
• It is recommended to use a nozzle having a diameter and a length specified by ISO 22241-4 and an auto
stop function to add DEF. When the specified nozzle is used, the magnet installed inside the filler port of the
tank cancels the wrong fluid addition prevention device, and you can add DEF. This mechanism prevents
addition of DEF into the fuel tank, addition of fuel into DEF tank, and spill of DEF from the filler port.
• When using a nozzle which is not conformed to ISO 22241-4, hold it in your hand and add DEF carefully
while checking the sight gauge.
• Add only DEF in clearly marked DEF tanks that have the blue cap.

METHOD FOR CHECKING TIRE PRESSURE

Measure the inflation pressure with tire pressure gauge while the tires are cool, before starting work.
Check the tires and rims for damage or wear, check the hub nuts (bolts) for loosening.
Proper inflation pressure varies with the contents of work, etc. For detail, see “TIRE PRESSURE”.

METHOD FOR CHECKING WINDOW WASHER FLUID SPOUTING OUT

Operate the window washer and check that the washer fluid spouts out normally.
• If the fluid does not spout out normally, clean the washer nozzle hole with a fine wire such as a safety pin.
• If the condition does not become normal, ask your Komatsu distributor to perform inspection and repair.

METHOD FOR CHECKING WIPER FUNCTION

Operate the wiper in the “Intermittent”, “Low”, and “High” mode and check that it operates and wipes normally.
• Operate the window washer to wet the glass, and check the operation of the windshield wiper.
• If the wiper does not wipe normally, the glass needs to be cleaned or the wiper blade needs to be replaced.
• If the condition does not become normal, ask your Komatsu distributor to perform inspection and repair.

METHOD FOR CHECKING MACHINE MONITOR

1. Turn the starting switch to ON (B) position.

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2. Check that all the monitors and gauges and centralized

warning lamp light up for approximately 2 seconds and the
alarm buzzer sounds for approximately 2 seconds.
Check that the engine tachometer swings.
If the lamps do not light up, there may be a failure in the
monitor or wire breakage. Ask your Komatsu distributor for
inspection.

METHOD FOR CHECKING HORN

Operate the horn switch and check that the horn sounds.
If there is any abnormality, ask your KOMATSU distributor for testing and repair.

METHOD FOR CHECKING DEFROSTER FUNCTION

• Operate the air conditioner and check that the air flows out of the vents properly onto the front glass.
If there is any abnormality, ask your KOMATSU distributor for testing and repair.
• Operate the rear heated wire glass switch and check that the rear glass surface is heated properly.
If there is any abnormality, ask your KOMATSU distributor for testing and repair.

METHOD FOR CHECKING LOCKS

Check that all places can be locked properly.
(For the locations of the locks, see “LOCK (3-208)”.)
If there is any abnormality, ask your KOMATSU distributor for testing and repair.

METHOD FOR CHECKING ALTERNATE EXIT OF CAB

Operate the open knob for alternate exit of cab, and check that the exit opens and closes properly.
If there is any abnormality, ask your KOMATSU distributor for testing and repair.

METHOD FOR ADJUSTING

METHOD FOR ADJUSTING OPERATOR'S SEAT
k WARNING
• Place the machine in a safe place when adjusting the position of the operator's seat.
Always set the work equipment lock lever to LOCK position (the pilot lamp in the switch is lit) to
prevent any accidental contact with the control levers.
• Adjust it before starting operation or when operators change shift.
• Adjust the position of the operator's seat so that you can depress the brake pedal fully with your
back against the seat backrest.

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METHOD FOR ADJUSTING SEAT UNIT IN FORE-AND-AFT DIRECTION

Operate the lever upward, set the seat to the desired position,
and then release the lever.
Fore-and-aft adjustment: 152.4 mm (12.7 mm x 12 stages)

METHOD FOR RECLINING SEAT

NOTICE
If the backrest is reclined too far, the headrest or seat belt anchor (when the 3-point seat belt (optional)
is installed) may contact the rear window glass, so move it to a position where it does not contact the
window glass.
1. Pull the lever upward, and move the backrest forward or
backward.
Sit with your back against the backrest when adjusting. If
your back is not on the backrest, it may suddenly return to
the original position.
Adjustment amount
Forward tilt: 21 °(any degree is acceptable if it is greater
than 21 °.)
Backward tilt: 33 °
2. After adjusting, release the lever.

METHOD FOR TILTING SEAT

Pull the lever up and move the front side of the seat cushion up
and down to the desired position, then release the lever.
Adjustment amount
Forward tilt: 5 °
Backward tilt: 5 °

METHOD FOR ADJUSTING WEIGHT AND HEIGHT OF SEAT

Turn the engine starting switch to ON position when performing adjustments since the air compressor built in the
seat is used for this adjustment.

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NOTICE
Do not operate the switch continuously for 1 minute or longer. Doing so can damage the air compres-
sor.
The seat height is adjusted pneumatically and in stepless.
Adjust the suspension strength and seat height by pressing the
switch.
Press left side (A) of switch: RAISE
Press right side (B) of switch: LOWER
Release the switch at desired height of the seat.
Adjustment amount: 152 mm
REMARK
When the seat is low or when the machine has not been used
for a while, it takes time to raise the seat to desired height,
since no air is in the suspension.
You can adjust the seat to desired height more quickly by
pressing the switch while reducing the load on the seat.

METHOD FOR ADJUSTING SEAT CUSHION IN FORE-AFTER DIRECTION

Operate the lever upward, set the seat cushion to the desired
position, then release the lever.
Fore-aft adjustment: 60 mm

METHOD FOR ADJUSTING HEADREST ANGLE

Move the headrest back and forth to set it to the desired angle.
Adjustment amount: 30 °

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METHOD FOR ADJUSTING HEADREST IN VERTICAL DIRECTION

Move the headrest up or down to the desired height.
Adjustment amount: 127 mm

METHOD FOR ADJUSTING ARMREST ANGLE

Turn the knob to adjust the armrest angle.
Amount of adjustment: 35 ° (Forward tilt 12 °, backward tilt
23 °)
REMARK
You can flip up the armrest.

METHOD FOR ADJUSTING LUMBAR SUPPORT

Turn the knob to the right or left, and give proper tension to the
waist part.

METHOD FOR ADJUSTING SUSPENSION DAMPER HARDNESS

By operating the knob, the damping force of the suspension damper can be adjusted.

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• To increase the damping force, direct the knob toward bot-

tom side (A) of the seat.
• To decrease the damping force, direct the knob toward top
(B) of the seat.
Adjustment amount
1st stage: at position (c)
2nd stage: at position (d)
3rd stage: at position (e)
4th stage: at position (f)
5th stage: at position (g)
REMARK
As for the hardness adjustment of suspension damper, 3rd
stage position (e) is preset as the best position for operator
comfort.
Accordingly, adjusting the knob to 3rd stage position (e) is rec-
ommended for usual operation.

1. When you want to decrease the vertical movement of the suspension, adjust the knob to 4th stage position
(f) or 5th stage position (g).
(The damper becomes harder.)
2. When you want to decrease the shock to the seat further, adjust the knob to 2nd stage position (d) or 1st
stage position (c).
(The damper becomes softer.)

METHOD FOR WARMING UP SEAT

When the switch is operated in the (A) direction, the heater in-
side the seat cushion is activated. When it is operated in the
(B) direction, the heater is turned off.
When the heater is being operated, the lamp inside the switch
lights up.
Turn off the switch when the temperature of cushion becomes
correct.

k CAUTION
• Using the heater for a long time may cause low tem-
perature burn (blister, etc.).
• Do not put heavy luggage on the cushion. Do not stick
the cushion with needles, nails, etc.
• Do not put blanket, cushion, or other heat-retaining
material on the seat cushion. Doing so may cause
overheat.
• If water or beverage, etc. spills on the seat cushion,
wipe it off with soft cloth, etc., and dry out the seat
cushion before using it.

REMARK
The heater has no timer function and is not turned off automatically. Be sure to turn the switch off after using the
heater.

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METHOD FOR REMOVING AND INSTALLING HEADREST

METHOD FOR REMOVING HEADREST
When the headrest is not necessary, remove it according to the following procedure.
1. Pull up the headrest until it stops.
2. Pull up the headrest strongly, and it will come out.

METHOD FOR INSTALLING HEADREST

1. Insert the headrest into the hole at the seat back.
2. Push down the headrest.

METHOD FOR ADJUSTING MIRRORS

k WARNING
Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure
the visibility and may be injured or may lead to a serious personal injury or death.

NOTICE
• Tighten the mirror mounting bolts securely to prevent the mirrors from coming off due to loosening
of the bolt.
Tightening torque of mirrors (A) and (B): 2.0 to 2.5 Nm {0.2 to 0.25 kgm}
• If the torque cannot be controlled, ask your Komatsu distributor for adjustment.

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Mirrors (A), (B)

Loosen bolt (1) of the mirror, then adjust the mirror to a position
which gives the best view from the operator's seat of the blind
spot at the right and left sides of the rear of the machine.
Adjust the mirror angle so that you can see a person who is
standing at the right or left rear end position of the machine (or
an object having the diameter of approximately 30 cm and the
height of approximately 1 m).

Install the mirror to a position where you can easily see the
hatched area in the figure.
The reference values of the visibility range are as follows.
Visibility range (left): 2500 mm
Visibility range (right): 2500 mm
Mirror (A) Hatched area (a) must be in view.
Mirror (B) Hatched area (b) must be in view.

METHOD FOR ADJUSTING REAR VIEW CAMERA

METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE
k WARNING
• Be sure to adjust the camera before starting work. If it is not adjusted properly, you cannot secure
the visibility and a serious personal injury or death may result.
• When adjusting the angle of the camera, prepare a scaffold first in order to provide a safe working
platform.
If you try to work standing on the counterweight, there is a danger of serious injury or death due to
falling off from the machine.
• Install only the Komatsu genuine camera.

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Adjusting rear view camera angle

Adjust the angle of the rear view camera so that people within
1 m away from the machine's rear part (W) is displayed in the
monitor at the operator's seat.

If the image on the monitor is not aligned correctly, adjust

mounting angle (A) of the rear view camera.
Angle (A) can be adjusted within the range from 37 to 52 deg.

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1. Loosen mounting bolts (1) (3 places) and adjust angle (A).

REMARK
A part of the machine is shown on the monitor screen.
2. After adjusting, tighten bolts (1) (3 places).

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CHECK REAR VIEW CAMERA GUIDE LINE

Check that the images on the rear view camera monitor are
normal as shown in the figure. Then confirm that machine width
reference line (C) matches to tire outside width (A), and hori-
zontal line (D) matches to position (B) that is 1.5 m away from
the rear end of the machine.
When the reference line is abnormal, change its setting to Non-
display and contact your Komatsu distributor.

METHOD FOR FASTENING AND UNFASTENING SEAT BELT

k WARNING
• Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If
it is worn or damaged, replace it.
• Even if no problem can be seen in the belt, replace the seat belt every 3 years from starting usage
or 5 years after manufacture whichever comes sooner. The date of manufacture of the belt is shown
on the back of the belt.
• Before operating, fasten the seatbelt.
• Be sure to use the seat belt during operation.
• Do not twist the seat belt when fastening.

REMARK
The date indicated on the seat belt is the manufactured date. It is the start of the 5-year period. It is not the start
of the 3-year period of actual usage.

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METHOD FOR FASTENING SEAT BELT

1. Sit in the seat and depress the brake pedal fully. Under this
condition, adjust the seat so that your back is fitted to the
backrest.
2. Sit on the seat, pull the belt on right side, then insert
tongue (1) into buckle (2) until a click is heard. Fasten the
seat belt so that it fits tightly, without being too tight.
3. Pull the belt to check that it is securely locked.

METHOD FOR UNFASTENING SEAT BELT

Press the red button of buckle (2).
REMARK
If the seat belt is not locked, the seat belt caution lamp lights up
on the machine monitor.

METHOD FOR ADJUSTING LEVER STAND

k WARNING
When adjusting the lever stand, make sure that the work equipment is locked (the pilot lamp in the
switch is lit).
If the multifunction mono-lever is touched by accident when adjusting the lever stand, the work equip-
ment may move unexpectedly, and cause a serious personal injury or death.

METHOD FOR ADJUSTING ARMREST HEIGHT AND ANGLE

Adjust the height and angle of the armrest (1) according to the following procedure.
1. Set the lock lever (2) of armrest (1) to FREE position (F).
The lock lever is loosened.
2. Hold the armrest (1) at the desired position.
Adjustment amount of height: 30 mm
Adjustment amount of angle: 44 °
3. Set the lock lever to LOCK position (L).
Armrest (1) is fixed.

REMARK
If tightening of the lock lever is insufficient, the armrest may move.
Tighten the lock levers (2 pieces) securely after adjusting the armrest.

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METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE

k WARNING
When starting the engine, check that the work equipment is securely locked (the pilot lamp in the switch
is lit).
If the multifunction mono-lever is touched by accident when starting the engine, the work equipment
may move unexpectedly, and this may lead to a serious injury or death.

Perform the check before starting the engine according to the following procedure.
1. Check that the battery disconnect switch (S) is in ON posi-
tion (I).

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

(A).

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3. Check that the directional lever (2) is in NEUTRAL position

(N).
REMARK
The engine can be started only when the directional lever
is in NEUTRAL position (N).

4. When the directional selector switch actuation switch (3) is

in ON position (A), check that the directional selector
switch (4) is in NEUTRAL position (N).
REMARK
The engine can be started only when the directional lever
(2) is in NEUTRAL position (N) and the directional selector
switch (4) is in NEUTRAL position (N) while the directional
selector switch actuation switch (3) is in ON position (A).

5. Check that the bucket is lowered to the ground.

If not, lower the bucket to the ground in the following procedure.
1) Check that the multifunction mono-lever is in “HOLD”
position.
2) Turn the starting switch (5) to ON position.
3) Cancel the work equipment lock (the pilot lamp in the
switch (6) goes out).
4) Operate the multifunction mono-lever, and lower the
bucket to the ground.
5) Check that the multifunction mono-lever is in “HOLD”
position.
6) Lock the work equipment (the pilot lamp in the switch
(6) lights up).
7) Turn the starting switch (5) to OFF position.

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MACHINE OPERATIONS AND CONTROLS OPERATION

6. Insert the key into starting switch (5) and turn it to ON posi-
tion (B).
7. Check that the machine monitor operates in the following
manner.
When the starting switch is turned to ON position to start
the engine, all the monitors, gauges and centralized warn-
ing lamp light up for approximately 2 seconds, and the
alarm buzzer sounds for approximately 2 seconds.
The engine tachometer swings once.
If the monitor does not light up, there may be a failure or
wire breakage. Ask your Komatsu distributor for inspection.
8. Check that the work equipment is locked (the pilot lamp in the switch (6) is lit).

METHOD FOR STARTING ENGINE

START ENGINE IN NORMAL WEATHER
k WARNING
• Start the engine only while sitting down in the operator's seat.
• Do not attempt to start the engine by short-circuiting the engine starting circuit.
Doing so may cause a fire or serious personal injury or death.
• Check that there is no person or obstacle in the area around the machine, then sound the horn and
start the engine.
• Exhaust gas is toxic.
When starting the engine in confined spaces, be particularly careful to ensure good ventilation.

NOTICE
• Do not accelerate the engine abruptly until it is
warmed up.
Do not operate the starting motor continuously for
more than 20 seconds.
• If the engine does not start, wait for 2 minutes or so,
and then try to start the engine again.
This machine is equipped with an engine automatic preheating
device that functions to start the engine preheating automati-
cally.
When the ambient temperature is low, the preheating pilot lamp
(2) lights up when the key in starting switch (1) is turned to ON
position to inform the operator that preheating has been started
automatically.

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OPERATION MACHINE OPERATIONS AND CONTROLS

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

When the ambient temperature is low, preheating pilot
lamp (2) lights up and automatic preheating is performed.
Keep the starting switch key (1) at ON position until pre-
heating pilot lamp (2) goes out.
The time that preheating pilot lamp (2) stays lit depends on
the ambient temperature as shown in the table.
Ambient temperature ( °C) Lighting time (sec.)
-1 to -15 0 to 30
Below -15 30

REMARK
Usually, the engine is preheated sufficiently by the automatic preheating. If it is needed to extend the pre-
heating time, turn the key in starting switch (1) to position (D) and hold it in the position.
Do not preheat the engine more than 30 seconds, however.
2. When preheating pilot lamp (2) does not light up, turn the
key in starting switch (1) to START position (C) after the
engine preheating has been completed.
The starting motor keeps running to start the engine.
Keep the key in starting switch (1) at position (C) to keep
running the starting motor until the engine starts.
REMARK
When the ambient temperature is low, fuel is not supplied
to the engine for 3 seconds to ensure lubrication of the en-
gine and to improve the durability after the key in starting
switch (1) is turned to START position (C), so the engine
does not start during this time.
3. When the engine starts, release the starting switch key (1).
The key returns automatically to ON position (B).

When the engine is started, white smoke may come out of the exhaust pipe. It is fine water particles which are
produced from moisture or water vapor and which seem white, thus it does not indicate an abnormality.
The smell of the exhaust gas is different from that of the conventional diesel machine because of the exhaust
gas filtering function.

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MACHINE OPERATIONS AND CONTROLS OPERATION

START IN COLD WEATHER

k WARNING
• Start the engine only while sitting on the operator's seat.
• Do not attempt to start the engine by short-circuiting the engine starting circuit.
Doing so may cause a fire or serious personal injury or death.
• Check that there is no person or obstacle in the area around the machine, then sound the horn and
start the engine.
• Exhaust gas is toxic.
When starting the engine in confined spaces, be particularly careful to ensure good ventilation.

NOTICE
• Do not accelerate the engine abruptly until it is
warmed up.
• This machine is equipped with the automatic warm-up
function to heat the coolant more quickly and the tur-
bo protect function to protect the turbocharger.
In cold weather startup, the engine speed may not
change for several seconds immediately after the
startup even if accelerator pedal (3) is depressed.
• If the machine is left for a long time with engine run-
ning at idle, inside of KCCV and blowby piping may be
frozen and blocked.
To prevent freeze, stop the engine or, if it is necessary
to run the engine at idle, apply the load from time to
time.
When the engine is started after it has been left at temperature
of approximately -20 °C for more than a half day, it takes time
to attain perfect combustion.
Operate the starting switch according to the following proce-
dure.
1. Turn the key in starting switch (1) to ON position (B).
When the ambient temperature is low, preheating pilot
lamp (2) lights up and automatic preheating is performed.
Keep the starting switch key (1) at ON position until pre-
heating pilot lamp (2) goes out.
The time that preheating pilot lamp (2) stays lit depends on
the ambient temperature as shown in the table.
Ambient temperature ( °C) Lighting time (sec.)
-1 to -15 0 to 30
Below -15 30

REMARK
Usually, the engine is preheated sufficiently by the automatic preheating. If it is needed to extend the pre-
heating time, turn the key in starting switch (1) to position (D) and hold it in the position.
Do not preheat the engine more than 30 seconds, however.

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OPERATION MACHINE OPERATIONS AND CONTROLS

2. After preheating pilot lamp (2) goes out, turn starting

switch key (1) to START position (C).
Keep the key in starting switch (1) at position (C) to keep
running the starting motor until the engine starts.
The starting motor keeps running to start the engine.
REMARK
• Do not operate the starting motor continuously for
more than 20 seconds.
• If the engine does not start, release your hand from
the starting switch, wait for 1 minute, and then start
the engine again.
3. After the engine starts and its speed increases, release
your hand from the key of starting switch (1).
The key returns automatically to ON position (B).
REMARK
When the engine is started, white smoke may come out of
the exhaust pipe. It is fine water particles which are pro-
duced from moisture or water vapor and which seem
white, thus it does not indicate a problem.
The smell of the exhaust gas is different from that of the
conventional diesel machine because of the exhaust gas
filtering function.
REMARK
Urea SCR system has the function of heating and keeping itself warm to prevent freezing of DEF.
If DEF is frozen, DEF system is automatically heated and thawed after the engine is started. The devices
do not operate until DEF is thawed and supplied, but this does not indicate any abnormality.
When the ambient temperature decreases to a level where DEF may freeze while the machine is in opera-
tion, DEF system is warmed automatically to prevent freezing. When the ambient temperature decreases to
a level where freezing of DEF is not preventable, the devices stop automatically, but this does not indicate
any abnormality.
If DEF freezes, thawing operation is performed automatically. Never heat DEF. Harmful ammonia gas may
be generated.

TURBOCHARGER PROTECTION FUNCTION

The turbo protect function protects the turbocharger by keeping the engine speed at approximately 1000 rpm or
less immediately after the engine is started.
When the turbo protect function and automatic warm-up function operate at the same time, the turbo protect
function is given priority.
• While the turbo protect function is operating, increase of the engine speed is restricted even if the accelera-
tor pedal is depressed.
• When the turbo protect function is canceled, the engine speed becomes the speed according to the de-
pressed level of the accelerator pedal.
• The relationship between the actuating time of the turbo protect function and the temperature of the engine
coolant is as shown in the table.
Coolant temperature
Turbo protect time (sec.)
( °C)
Min. 10 0
10 to -30 Variable between 0 and 20

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METHOD FOR OPERATING AUTOMATIC WARM-UP SYSTEM

When starting the engine, if the engine coolant temperature is
20 °C or less, the warming-up operation (engine speed:
1000 rpm) is performed automatically and stopped when the
engine coolant temperature increases to 30 °C or higher. (En-
gine speed 825 rpm)
(X): Engine speed ( rpm)
(Y): Coolant temperature ( °C)

METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE

k WARNING
• If there has been any emergency stop, abnormal actuation, or other trouble, turn the starting switch
key to OFF position.
• If you cannot stop the engine by turning the starting switch to OFF position, use the engine shut-
down secondary switch to stop the engine.
• If the work equipment is operated without sufficient warming-up operation of the machine, response
of the work equipment to movement of the control lever will be slow, and the work equipment may
not respond as the operator desires. Be sure to perform the warm-up operation.
Particularly in a cold weather, be sure the warm-up operation is completed.
• If the machine is operated without sufficient warming-up operation, sensors may break because of
frozen DEF tank.
• Keep away from the exhaust pipe while the engine is running and immediately after stopping the
engine.
Keep combustible materials away from the exhaust pipe outlet.

METHOD FOR CHECKING STARTING CONDITION AND UNUSUAL NOISE OF

ENGINE
• When starting the engine, check that the engine causes no abnormal noise and that it starts up easily and
smoothly.
• Check that there is no abnormal noise when the engine is idling or when the engine speed rises slightly.
When there is an abnormal noise at the engine startup and if that condition continues, the engine may be dam-
aged. In that case, ask your Komatsu distributor to check the engine as soon as possible.

METHOD FOR CHECKING LOW-SPEED RUN AND ACCELERATION OF ENGINE

When stopping the machine during the normal traveling operation, check that the engine does not hunt or stop
suddenly.
When the accelerator pedal is depressed, check that the engine speed rises smoothly.
• Perform these checks in a safe place, watching out for danger in the surroundings.
• When the engine performs very badly at low idle and in the acceleration and if that condition continues, it
may damage the engine or confuse the operator's sense of driving or lower the braking efficiency, and as a
result lead to an unexpected accident. In that case, ask your Komatsu distributor to check the engine as
soon as possible.
REMARK
• The smell of the exhaust gas is different from that of the conventional diesel engine because of the exhaust
gas aftertreatment devices.
• White smoke may be discharged for a short time immediately after the engine is started or during the after-
treatment devices regeneration in the cold season, but this is not a failure.

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METHOD FOR TESTING PARKING BRAKE

Check that the parking brake works properly.
If any problem is found in operation, ask your Komatsu distributor for adjustment.

METHOD FOR CHECKING BRAKE

Drive the machine forward and in reverse slowly on a level ground with no obstacles around and check the
brake performance.
If any problem is found in operation of the brake, ask your Komatsu distributor for adjustment.

METHOD FOR CHECKING CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR

Depress the brake pedal fully and check that the pedal is not too close to the floor. Also check that the feeling
when operating the brake pedal is normal.
If any problem is found, ask your Komatsu distributor for adjustment.

METHOD FOR CHECKING ABNORMAL POINTS DETECTED UP TO PREVIOUS

DAY
Check the area which was abnormal when the machine was used previous day.
If there is any abnormality, ask your KOMATSU distributor for testing and repair.

METHOD FOR RUNNING-IN THE NEW MACHINE

NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory.
However, operating the machine under full load before running in the machine can adversely affect the
performance and shorten the machine life.
Be sure to run in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the descriptions in this manual, then run in the machine while paying atten-
tion to the following points.
• Idle the engine for 5 minutes after starting it up.
• Avoid operation with heavy loads or at high speeds.
• Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden
stops, and sudden changes in direction of the machine.

METHOD FOR OPERATIONS AFTER STARTING ENGINE

Do not start operating the machine immediately after the engine starts. First, perform the following operations
and checks.
NOTICE
Do not accelerate the engine abruptly until it is warmed up.
Do not run the engine at low idle or high idle continuously for more than 20 minutes.
If it is necessary to run the engine at low or high idle, apply a load from time to time or run it at a mid-
range speed.

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1. Depress the accelerator pedal (1) lightly and run the en-
gine at a medium speed for approximately 5 minutes with
no load.

Only in cold weather, perform the following operation to warm up the hydraulic oil.
2. Check that the engine rotation is smooth, then cancel the
work equipment lock (turn off the pilot lamp in the switch)
with the work equipment lock switch (2) after the warm-up
operation.

3. Operate the multifunction mono-lever to “TILT” position (e)

and to “HOLD” position (b) repeatedly to warm up the hy-
draulic oil.
Duration of relieving at “TILT” position (e) should be within
10 seconds.
Oil reaches the relief pressure through the above opera-
tions, and hydraulic oil gets warmer in a shorter time.

4. Turn the steering wheel slowly approximately 10 times to

the right and left to warm up hydraulic oil in the steering
valve.

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k WARNING
A time lag might result until the machine stops after the turning operation if you turn the steering
wheel and stop turning it at certain position while the oil temperature is low.
In such case, use the frame lock bar to secure safety, and perform the warm-up operation in a large
place.
At that time, be sure not to continuously relieve the oil pressure in the circuit for more than 5 sec-
onds.

NOTICE
Turn the steering wheel a little and stop at certain position. Check that the machine has turned by
the angle corresponding to the turning angle of the steering wheel.
5. After the warm-up operation, check that the instruments
and pilot lamps are normal.
If any problem is found, perform maintenance or repair.
Run the engine with a light load until the pointers of engine
coolant temperature gauge (3) and HST oil temperature
gauge (4) indicate the green range.
6. Check for abnormal exhaust gas color, noise, or vibration.
If any abnormality is found, contact your Komatsu distribu-
tor.
REMARK
The cooling fan speed varies according to the following
conditions, but it is not abnormal.
The cooling fan speed increases when the hydraulic oil
temperature or engine coolant temperature is high.
The cooling fan rotates at a fixed speed in proportion to
the engine speed, regardless of any oil or coolant temper-
ature while it is rotating in reverse.

METHOD FOR STOPPING ENGINE

k WARNING
Keep away from the exhaust pipe immediately after stopping the engine.

NOTICE
If the engine is abruptly stopped before it has cooled
down, service life of the engine parts may be reduced. Do
not stop the engine abruptly except the case in an emer-
gency.
If the engine is overheated, do not try to stop it abruptly
but run it at medium speed to allow it to cool down gradu-
ally, and then stop it.
If the engine is stopped during the aftertreatment devices
regeneration, the components may be damaged.
When stopping the engine, stop the aftertreatment devices
regeneration first, and run the engine at low idle for ap-
proximately 5 minutes. Then stop the engine.
Stop the engine according to the following procedure.
1. Run the engine at low idle for approximately 5 minutes to cool down the engine gradually.

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MACHINE OPERATIONS AND CONTROLS OPERATION

2. Turn the key of starting switch (1) to OFF position (A), and
stop the engine.

3. Remove the key from starting switch (1).

REMARK
• After the engine is stopped, DEF in DEF injector and
pump is automatically purged and returned to the tank
to prevent malfunction of the devices caused by freez-
ing of DEF or deposition of urea.
For this purpose, the devices keep operating for sev-
eral minutes after starting switch (1) is turned to OFF
position, and this does not indicate abnormality.
In addition, the system operating lamp lights up while
devices are operating to purge DEF to the tank. Do
not turn the battery disconnect switch to OFF position
while the system operating lamp is lit. After DEF has
been purged completely, the devices stop automatical-
ly.
• If the starting switch (1) key is turned to OFF position
(A) while the engine is still hot, guidance (2) may be
displayed on the machine monitor. To cool down the
engine before stopping, run it at low idle the next time
and after, because it may cause damage to the devi-
ces.

METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE,

AND SHIFTING GEAR) AND STOPPING MACHINE
METHOD FOR MOVING MACHINE
k WARNING
• Always disengage the frame lock bar during traveling. If it is not disengaged, the steering becomes
inoperative and this may lead to serious personal injury or death.
• Before moving the machine off, check that the area around the machine is safe, then sound the
horn before starting.
• Do not allow anyone to enter the area around the machine.
• Clear any obstacles from the travel path.
• There is a blind spot behind the machine, so be extremely careful when driving the machine in re-
verse.
• Do not try to make directional change abruptly while the engine speed is high.

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OPERATION MACHINE OPERATIONS AND CONTROLS

1. Check that the caution lamp (1) is not lit.

2. Check that the multifunction mono-lever (2) is in “HOLD”

position.

3. Cancel the work equipment lock (the pilot lamp in the

switch goes out) with the work equipment lock switch (3).

4. Operate the multifunction mono-lever (2) to set the work

equipment to the travel posture as shown in the figure.
(A): 30 cm

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MACHINE OPERATIONS AND CONTROLS OPERATION

5. Depress the R.H. brake pedal (4), and set the parking
brake switch (5) to OFF position (C) to release the parking
brake.
Keep the R.H. brake pedal (4) depressed.
REMARK
When the parking brake remains applied even if the park-
ing brake switch (5) is at OFF position (C), turn the parking
brake switch (5) to ON position (B), then turn it to OFF po-
sition (C) again.

6. Set the speed range selector switch (6) to the desired po-
sition.
Position (a): 1st speed
Position (b): 2nd speed
Position (c): 3rd speed
Position (d): 4th speed

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

Position (F): FORWARD
Position (N): NEUTRAL
Position (R): REVERSE
Check that the backup alarm sounds when the directional
lever is set to REVERSE.
If the backup alarm does not sound, ask your Komatsu dis-
tributor for repair.
REMARK
You can also use the directional selector switch (7) to set
the travel direction to FORWARD, NEUTRAL, and RE-
VERSE.
Position (F): FORWARD
Position (N): NEUTRAL
Position (R): REVERSE
Set the directional lever (6) to NEUTRAL position and the
directional selector switch actuation switch (8) to ON posi-
tion (A) when selecting FORWARD, NEUTRAL or RE-
VERSE with the directional selector switch (7).

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8. Release the R.H. brake pedal (4), then depress the accel-
erator pedal (9) to move off.

METHOD FOR SELECTING SPEED RANGE

k WARNING
Avoid an abrupt shifting of the speed range while traveling at high speed. Reduce the speed by releas-
ing the accelerator pedal always before selecting the speed range.

Perform the selection of the speed range as follows.

Move the speed range selector switch (1) to the desired posi-
tion to select the speed range.
Position (a): 1st speed
Position (b): 2nd speed
Position (c): 3rd speed
Position (d): 4th speed
REMARK
• If the speed range selector switch is operated slowly or is
stopped in-between speed ranges, the centralized warning
lamp may light up and the alarm buzzer may sound. This
is not a failure in this case.
Operate the speed range selector switch so that the selec-
tion of the speed range is completed within 2 seconds.
• When the machine is traveling at high speed, if the speed
range selector switch is operated to a slower speed range
such as from 4th to 2nd and from 3rd to 2nd while de-
pressing the accelerator pedal, the shift down is not per-
formed in order to protect overrun of the engine.
In such case, the centralized warning lamp lights up and
the alarm buzzer sounds.
If the alarm buzzer sounds, release the accelerator pedal
immediately, depress the brake pedal to reduce the speed
and then select the speed range.

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METHOD FOR SWITCHING BETWEEN FORWARD AND REVERSE

k WARNING
• Check the safety in the direction which the machine moves into when switching the travel direction
between FORWARD and REVERSE.
The area behind the machine is a blind spot.
Pay attention particularly when traveling in reverse.
• Do not make a directional change while the machine is traveling at a high speed.
When switching the direction, depress the brake pedal to reduce the travel speed sufficiently, then
switch the direction. (Max. 13 km/h)
• When driving the machine downhill through inertia, set the directional lever to the position that
matches the machine traveling direction. If the direction lever is set to the direction opposite to that
of the machine travel, engine stall can result and it is very dangerous.

You can switch the travel direction without stopping the machine.
If you try to make a directional selection while the machine is
traveling at a high speed (when 3rd or 4th speed is used), the
centralized warning lamp lights up and alarm buzzer sounds if
the travel speed and engine speed are in hatched area of the
table.
If the alarm buzzer sounds, depress the brake pedal immedi-
ately to reduce the travel speed sufficiently, then make a direc-
tional selection.
(X): Travel speed ( km/h)
(Y): Engine speed ( rpm)

Directional selection by lever operation

Set the directional lever (1) to a desired position.
Position (F): FORWARD
Position (N): NEUTRAL
Position (R): REVERSE
Check that the backup alarm sounds when the directional lever
is set to REVERSE.
If the backup alarm does not sound, ask your Komatsu distribu-
tor for repair.
REMARK
If you operate the directional lever slowly or stop it at midway
between the lever positions, the centralized warning lamp may
light up and the alarm buzzer may sound. In this case, there is
no failure, but operate the directional lever so that directional
change is completed within 2 seconds.

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Directional selection by switch operation

k WARNING
When shifting the directional lever (1) to FORWARD (F) or
REVERSE (R) position while the directional selector switch
actuation switch (3) is in ON position, the machine travels
forward or in reverse in accordance with the directional
lever (1) regardless of the position of the directional selec-
tor switch (2).
Be careful to operate because the operation of the direc-
tional lever (1) is prior.

1. Set the directional lever (1) to NEUTRAL (N) position.

2. Set the directional selector switch (2) to NEUTRAL posi-

tion (N).

3. Turn the directional selector switch actuation switch (3) to

ON position (A).

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MACHINE OPERATIONS AND CONTROLS OPERATION

4. Set the directional selector switch (2) to FORWARD (F) or

REVERSE (R) position.

REMARK
When shifting the directional lever (1) to FORWARD (F) or REVERSE (R) position while the directional se-
lector switch actuation switch (3) is in ON position, the machine travels forward or in reverse in accordance
with the directional lever (1) regardless of the position of the directional selector switch (2).
(The operation of the directional lever is given priority.)
When using the directional selector switch (2) again, set the directional lever (1) and the directional selector
switch (2) to NEUTRAL (N) position.
The switch and the lever are in the following condition
when the directional selector pilot lamp on the machine
monitor lights up in yellow. Set them to the proper posi-
tions.
• When the directional lever (1) is not in NEUTRAL (N)
position
The directional selector pilot lamp lights up in yellow,
the centralized warning lamp lights up, and the alarm
buzzer start sounding intermittently at the same time.
In this condition, the machine travels forward and re-
verse in accordance with the directional lever (1) posi-
tion. Set the directional lever (1) to NEUTRAL (N) position.
• When the directional selector switch (2) is in FORWARD (F) or REVERSE (R) position when starting
the engine.
The directional selector pilot lamp lights up in yellow, the centralized warning lamp lights up, and the
alarm buzzer start sounding intermittently at the same time. The engine does not start under this condi-
tion. Set the directional selector switch (2) to NEUTRAL (N) position.

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METHOD FOR STOPPING MACHINE

k WARNING
• Stop the machine gradually. Avoid a sudden stop.
• Do not park the machine on a slope. If it is unavoida-
ble to park the machine on a slope, place the machine
at a right angle to the slope face, lower the bucket to
the ground, and then chock the tires to prevent the
machine from moving.
• If the multifunction mono-lever is touched by accident,
the work equipment or machine may move suddenly,
and it may cause a serious accident. Before leaving
the operator's seat, be sure to lock the work equip-
ment by pressing the work equipment lock switch (the
pilot lamp lights up).
• Keep depressing the brake pedal until the parking
brake pilot lamp lights up on the machine monitor
even when the parking brake switch has been turned
on.

NOTICE
Never use the parking brake switch to brake the machine when the machine is traveling except in an
emergency. Stop the machine, and then apply the parking brake.
1. Release the accelerator pedal (1), then depress the brake
pedal (2) to stop the machine.

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MACHINE OPERATIONS AND CONTROLS OPERATION

2. Set the directional lever (3) and the directional selector

switch (4) to NEUTRAL (N) position.

3. Set the parking brake switch (5) to ON position (A), and

apply the parking brake.

4. After the parking brake pilot lamp lights up, release the
brake pedal gradually.

METHOD FOR STEERING MACHINE

k WARNING
• Avoid steering during high-speed travel or steering on a steep slope, since it is dangerous.
• Do not stop the engine during travel, since the steering operation becomes heavy if the engine is
stopped.
It is particularly dangerous if the engine is stopped while the machine is traveling on slopes, so
never try such practice.
If the engine stops while traveling, place the machine immediately in a safe place.

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OPERATION MACHINE OPERATIONS AND CONTROLS

• When the machine is traveling, turn the steering wheel (1)

to the desired direction, then the machine turns to the di-
rection.
Front and rear frames of this machine is articulated around
the connection pin (center pin) at which the 2 frames are
connected with each other and the rear wheels follow the
trace of the front wheels.

• Turn the steering wheel lightly as it follows the turning of machine.

NOTICE
When steering the machine fully, if the steering wheel
is turned to its stroke end, do not try to turn it further.
Check that the play (a) of steering wheel is 60 mm or
less, and that the operation of steering wheel is nor-
mal. If any problem is found, ask your Komatsu dis-
tributor for inspection.

HANDLE SECONDARY STEERING SYSTEM

k CAUTION
• Do not actuate the secondary steering except in trou-
ble or checking the function.
• When using the secondary steering, limit the travel
speed to 5 km/h or less.

The secondary steering pilot lamp (green) (1) lights up to in-

form the operator that the secondary steering system has been
actuated.
The secondary steering system is designed to enable the turning (steering) operation under the following condi-
tions.
• Traveling while steering system is faulty
• Coasting while engine is stopped
REMARK
The secondary steering system does not operate while the machine is stopped.
The steering low oil pressure pilot pump (red) (2) lights up
when the steering pressure is low.
While the engine is stopped, the steering pressure is low and
the steering low pressure pilot lamp (red) (2) lights up, but this
does not indicate any abnormality.
If the secondary steering system detects lack of oil pressure in
the steering system while the engine is running, the steering
low oil pressure pilot pump (red) (2), the steering oil pressure
caution lamp (red) (3), and the centralized warning lamp (4)
light up, and the alarm buzzer sounds intermittently.
The steering oil pressure caution lamp (red) (3) lights up to in-
form the operator that there is a failure in the steering system.

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MACHINE OPERATIONS AND CONTROLS OPERATION

If the steering oil pressure caution lamp (red) (3) lights up, move the machine immediately to a safe place and
stop it there.
Do not operate the machine until the cause is identified and it is repaired.
REMARK
When engine is running at low speed and when you use some hydraulic system functions, the steering low oil
pressure pilot pump (red) (2) may light up temporarily. There is no problem if the lamp is lit only momentarily.
When the secondary steering system detects the recovery of the oil pressure in the steering system, the secon-
dary steering system stops its actuation.

METHOD FOR OPERATING WORK EQUIPMENT

k WARNING
Never perform the boom RAISE operation with the machine articulated and the bucket full. There is a
danger that the machine may tip over.

NOTICE
Even if the engine is stopped, if the starting switch is at ON position and lock of the work equipment is
canceled (pilot lamp is not lit), the work equipment can move.
The multifunction mono-lever (1) is used to operate the boom
and bucket in the following manners.

METHOD FOR OPERATING BOOM

The multifunction mono-lever is used to operate the boom.
NOTICE
Do not use “FLOAT” position when lowering the bucket.
Use “FLOAT” for leveling work.
Position (a): RAISE
When the multifunction mono-lever is pulled further from the
“RAISE” position, the lever stops in that position.
When the remote boom positioner is enabled, the boom stops
at the preset position and the lever returns to “HOLD” position
at the same time.
The boom stops at the highest position and the lever returns to
“HOLD” position at the same time when the remote boom posi-
tioner is disabled.
Position (b): HOLD
The boom remains in the position where it was stopped.
Position (c): LOWER
Position (d): FLOAT
The boom moves freely under external force. When the multi-
function mono-lever is set at “FLOAT” position, the lever stops
in that position.

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OPERATION MACHINE OPERATIONS AND CONTROLS

METHOD FOR OPERATING BUCKET

Position (e): TILT
When the multifunction mono-lever is pulled further from the
“TILT” position, the lever stops in that position. As soon as the
bucket reaches the position preset by the bucket positioner, the
lever returns to the “HOLD” position.
Position (b): HOLD
The bucket remains in the position where it was stopped.
Position (f): DUMP

PRECAUTIONS FOR OPERATION

PERMISSIBLE WATER DEPTH
When operating the machine in water or on swampy ground,
do not move it to a place where the water depth is beyond the
permissible level (up to the bottom surface of axle housing (1)).
After finishing the operations, wash the machine and lubricate
the parts that have been exposed to water.
If the brake creaks, change all of the axle oil.

IF BRAKE DOES NOT STOP MACHINE MOVE

If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine.
NOTICE
If the parking brake was used as a secondary brake, ask your Komatsu distributor to inspect the park-
ing brake system for any trouble.

PRECAUTIONS WHEN TRAVELING ON SLOPES

LOWER CENTER OF GRAVITY WHEN STEERING MACHINE
When turning the machine on a slope, lower the work equipment to lower the center of gravity before turning.
Turning on a steep slop is dangerous and, thus, prohibited.

TRAVEL DOWNHILL
If you use the foot brake too frequently during downhill travel, the brake may be overheated and damaged.
Use the accelerator pedal effectively for better braking performance during traveling.
If the brake oil temperature caution lamp lights up and the alarm buzzer sounds intermittently because of fre-
quent use of the brake, take proper actions according to “BRAKE OIL TEMPERATURE CAUTION LAMP” in
“EXPLANATION OF COMPONENTS”.

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MACHINE OPERATIONS AND CONTROLS OPERATION

ACTIONS IF ENGINE STOPS

If the engine stops on a slope, apply the parking brake immediately, lower the work equipment and stop the ma-
chine. For restarting the engine, set the directional lever and the directional selector switch to NEUTRAL posi-
tion (N).

PRECAUTIONS FOR TRAVELING

A long distance travel at high speed can heat the tires extremely and cause premature damage on them. Avoid
it as long as possible.
If the machine must be driven for a long distance, take the following precautions.
• Observe the regulations related to this machine, and drive carefully to assure safety.
• Before driving the machine, perform the checks before starting.
• The most suitable tire pressure and travel speed differ according to the tire type and condition of the travel
surface. Contact your Komatsu distributor or tire dealer.
• The following shows the appropriate tire inflation pressure and travel speed when the machine is equipped
with the standard tires (20.5R25☆) and runs on the paved surface.
Inflation pressure: Front wheel 425 kPa {4.25 kg/cm2, Rear wheel 400 kPa {4.0 kg/cm2}
Travel speed14 km/h
• Check the tire inflation pressure before driving, when the tires are cool.
• Stop the machine for 30 minutes after the travel of 1 hour, and check the tires and each part for any abnor-
mality. Check the oil level and coolant level as well.
When stopping the machine in extremely cold areas, do as follows.
Do not stop the engine abruptly to prevent the radiator coolant temperature from rising sharply. Cool the
radiator coolant down gradually before stopping the engine.
• Always travel with the bucket empty.
• Never travel with calcium chloride or dry ballast in the tires.

PAY ATTENTION TO DEF LEVEL

Before working on a slope or traveling on a rough ground, check DEF tank and add sufficient amount of DEF as
necessary. If the remaining DEF level becomes low, sudden drop of its level or abnormality in urea SCR system
may be detected. If DEF level caution lamp or DEF system caution lamp lights up in red, move the machine to a
level place immediately and add DEF.

RECOMMENDED APPLICATIONS
In addition to the following, it is possible to further increase the range of applications by using various attach-
ments.

DIGGING WORK
k WARNING
• Never perform the digging or scooping operation with the machine articulated. There is a danger
that the machine may tip over.
• Never perform the boom RAISE operation with the machine articulated and the bucket full. There is
a danger that the machine may tip over.
• If the ECSS switch is turned on during travel or with the work equipment raised, the machine starts
moving instantly. Take care.
• If the machine is operated with the ECSS switch ON, the work equipment may start moving at the
moment when the ECSS is actuated. Take care.
• When the boom is below the level position, if the bucket TILT operation is performed further from
the tilt end, the boom may rise. If the bucket DUMP operation is performed just after this, the boom
may lower a little. Take care.

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OPERATION MACHINE OPERATIONS AND CONTROLS

NOTICE
If the tires slip, the tire life will be reduced, so operate the machine avoiding tire slippage.

LOAD STOCK PILES

When loading the stockpile, drive the machine forward as shown below to scoop them. Reduce the load by
slightly raising the bucket if tire starts slipping due to the heavy load.
1. Push the bucket into the stockpile as driving the machine
forward.

2. When the bucket has dug into the stockpile deeply

enough, set the multifunction mono-lever to the boom
“RAISE” position as driving the machine forward.
Make the bucket full by setting the multifunction mono-lev-
er to the bucket “TILT” position from time to time.
Try to scoop the material in the center of the bucket so that
the load does not become uneven.

3. When it is hard to thrust the bucket into the stockpile,

move the bucket edge upward and downward by shifting
the multifunction mono-lever to the right and left .

DIG AND LOAD ON HORIZONTAL SURFACE

• When digging the ground in digging and loading work on a level ground, set the bucket cutting edge facing
down slightly as follows and drive the machine forward. Always be careful not to load the bucket on one
side.
• The 1st in the speed range is appropriate.

k CAUTION
Do not set the bucket cutting edge downward more than 20 °.

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MACHINE OPERATIONS AND CONTROLS OPERATION

1. Set the cutting edge slightly downward from the horizontal.

2. Drive the machine forward and dig soil and sand bit by bit
as if they are ripped off by tilting the multifunction mono-
lever slightly forward.

3. Keep on driving the machine forward while adjusting the

digging depth by using the multifunction mono-lever.
When you perform digging by use of the bucket, avoid ap-
plying the digging force only to one side of the bucket.

LEVELING WORK
NOTICE
• Always drive the machine in reverse when performing leveling work.
When it is unavoidable to drive the machine forward for the leveling work, do not set the bucket
dumping angle to more than 20 °. The work equipment may be damaged.
• Keep ECSS switch turned OFF during leveling work.
1. Scoop earth and sand into the bucket and then, while driv-
ing the machine in reverse, tilt the bucket forward to dump
earth and sand bit by bit to spread them.
2. When leveling the ground, tilt the bucket forward so that
the bucket cutting edge touches the ground, then drag the
bucket by driving the machine in reverse.
3. When performing finish leveling, scoop earth and sand into
the bucket, set the boom to FLOAT position with the buck-
et horizontal, and reverse the machine.

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OPERATION MACHINE OPERATIONS AND CONTROLS

DOZING WORK
k CAUTION
Never set the bucket to DUMP position when performing the dozing operation. The work equipment may
be damaged.

When performing dozing operation, set the bottom of the bucket parallel to the ground surface.

LOAD-AND-CARRY OPERATION
k WARNING
• When carrying a load, lower the bucket to lower the center of gravity of the machine and drive.
• If the ECSS switch is turned ON during travel or with the work equipment raised, the machine starts
moving instantly. Take care.
• If the machine is operated with the ECSS switch ON, the work equipment may starts moving at the
moment when the ECSS is actuated. Take care.

NOTICE
When traveling continuously in load-and-carry operation,
choose the appropriate 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.
Consult your Komatsu distributor or tire dealer.
The load and carry method for wheel loaders consists of a cy-
cle of scooping → hauling → loading (into a hopper, glory hole
etc.).
Maintain the travel road constantly in good condition.

LOADING WORK
Select an efficient loading method which minimizes the number of turns and travel distance according to the job
site.

k WARNING
• Maintain the ground of job site level. Do not perform sudden steering or braking while the boom is
being raised with the bucket loaded. This is dangerous.
• Never thrust the work equipment into the target material (soil or crushed rock) when the machine is
traveling at high speed. This is dangerous.
• If the ECSS switch is turned on during travel or with the work equipment raised, the machine starts
moving instantly. Take care.
• If the machine is operated with the ECSS switch ON, the work equipment may start moving at the
moment when the ECSS is actuated. Take care.
• When the boom is below the level position, if the bucket TILT operation is performed further from
the tilt end, the boom may rise. If the bucket DUMP operation is performed just after this, the boom
may lower a little. Take care.

NOTICE
• If the tires slip, their service lives will be shortened. Take care that the tires do not slip during opera-
tion.
• Avoid excessive shaking of the bucket.

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CROSS DRIVE LOADING

When performing digging, set the wheel loader at a right angle
to the target stock pile. After digging in and scooping up the
load, drive the machine straight back in reverse, then bring the
dump truck in between the stock pile and the wheel loader.
This approach minimizes the time required for loading, cuts the
cycle time short and is efficient.

V-SHAPE LOADING
Park a dump truck at an angle of approximately 60 ° to the
scooping direction of the wheel loader. After scooping the soils,
back the wheel loader in such direction that it is at a right angle
to the dump truck and then move the machine forward to load
the soils onto the dump truck.
The smaller the turning angle of the wheel loader is, the more
efficient the operation becomes.
Before raising the boom to the maximum height after filling the
bucket with load, shake the bucket near the ground to stabilize
the load, then raise the bucket. This will prevent the load from
spilling to the rear.

PRECAUTIONS FOR FORKING WORK

When scooping soils up onto a pile, be careful not to let the rear counterweight come into contact with the
ground.
Do not set the bucket to DUMP position when piling-up loads.

LOW FUEL CONSUMPTION OPERATION

The fuel efficiency is better in 4th speed than in 3rd speed when performing the load-and-carry operation, cross
drive loading, V-shape loading, and the normal travel with travel speed 10 km/h or higher.

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The fuel efficiency and the work efficiency are better in the traction mode “Auto” than in traction mode “MAX”.

METHOD FOR ADJUSTING WORK EQUIPMENT POSTURE

k WARNING
• Place the machine on a level ground and move parking
brake switch from OFF position (B) to ON position (A)
with brake pedal depressed to apply parking brake se-
curely, and then confirm that the machine is stopped
completely.
• Put blocks in front of and behind the tires.
• Secure the front and rear frames with the frame lock
bar.
• Always hang the warning tag on the multifunction
mono-lever.
• Do not enter under the work equipment while the
boom is raised.

The bucket can be stopped automatically at the desired height with the remote boom positioner (the boom must
be higher than the boom horizontal position) and at the desired digging angle with the bucket positioner.
The bucket is adjustable to the desired position according to the operating condition.

REMOTE POSITIONER
This machine is equipped with the function of the remote boom positioner.
REMARK
If the remote positioner is effective, the remote positioner pilot
lamp lights up.

METHOD FOR OPERATING RAISE REMOTE BOOM POSITIONER

1. Set the boom to a desired RAISE stop position above the
horizontal.

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MACHINE OPERATIONS AND CONTROLS OPERATION

2. Return the multifunction mono-lever to “HOLD” position

(b).
3. Press (A) of the remote positioner switch (1).
A “beep” sounds and the position is set.

Operation checkup procedure

• Lower the boom once, operate the multifunction mono-lever to the position (RAISE detent position) where
the lever is further pulled than “RAISE” position, and then release your hand from the lever.
• The boom rises and then stops at the moment when the multifunction mono-lever returns from the RAISE
detent position to “HOLD” position.
REMARK
• When the multifunction mono-lever is set to RAISE detent position, if the boom is very close to the position
specified by the positioner (approximately within 2 °), the lever is not stopped at the RAISE detent position.
• For the boom RAISE detent function, see “BOOM RAISE DETENT SETTING (3-67)”.

METHOD FOR RELEASING RAISE REMOTE BOOM POSITIONER

1. Raise the boom above the horizontal level.

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2. Return the multifunction mono-lever to “HOLD” position

(b).
3. Hold down (A) of the remote positioner switch (1) for 1
second or longer.
A “beep” sounds and the stop position is reset.
If it is reset, when the multifunction mono-lever is set to the
position where it is pulled further than the “RAISE” posi-
tion, as soon as the boom returns from the position where
it is pulled further than “RAISE” position to “HOLD” position
near the maximum height, the boom stops.

If the remote positioner is effective, the remote positioner pilot

lamp lights up on the machine monitor.

METHOD FOR ADJUSTING BUCKET POSITIONER

1. Lower the bucket to the ground.
2. Return the multifunction mono-lever to “HOLD” position ac-
cording to the desired digging angle.
3. Press the work equipment lock switch and lock the work
equipment (the pilot lamp in the switch is lit).
4. Stop the engine.

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5. If the attachment selector switch is equipped, turn the

switch to the bucket position (A).

6. Loosen the nut (1). Adjust the position of the proximity

switch (3) so that the rear end (A) of the bar (2) and the
center point of sensory surface (B) of proximity switch (3)
are within the range "a".
a: 37 to 43 mm

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7. Adjust the range "c" with nut (1) so that the tip (C) of pro-
tector (5) protrudes 0.5 to 1.0 mm from the sensory sur-
face (B) of all proximity switches (3).
8. Loosen the bolt (4), and adjust the clearance "d" between
the bar (2) and the sensory surface (B) of all proximity
switches (3) so that it is within 3 to 5 mm, and fix it.
Tightening torque: 14.7 to 19.6 Nm {1.5 to 2.0 kgm}

9. After adjustment, run the engine to raise the boom. Check that the lever automatically returns to “HOLD”
position at desired digging angle when the bucket is tilted back after the bucket DUMP operation.
REMARK
For more accurate check, keep the HST oil temperature equal to those when the machine is actually oper-
ated.

METHOD FOR CHECKING BUCKET ANGLE

You can check the bucket angle during the operation with the
indicator at the top right side corner of the bucket.
(A) Top face of indicator
Top face (A) of the indicator is in parallel with the cutting edge.
(B) Side face of indicator
Side face (B) of the indicator is at a right angle to the cutting
edge.

PZ AUTO TILT-IN
This machine employs the structure to keep the tilt angle parallel to the ground while raising or lowering the
boom. The work performance with attachment such as fork, etc. is improved significantly.
This machine provides the PZ auto tilt-in function with which the bucket is automatically tilted according to the
boom RAISE operation for loading work. Select an appropriate setting of PZ auto tilt-in corresponding to the op-
eration environment so that the spillage can be reduced.
When the load is likely spilled out toward DUMP side
When the load tends to be spilled to DUMP side, set the PZ au-
to tilt-in setting to “Heavy”.

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MACHINE OPERATIONS AND CONTROLS OPERATION

When the load is likely spilled out toward TILT side

If the load tends to be spilled to TILT side while raising the
boom to the maximum height on uphill, set the PZ auto tilt-in
setting to “Light”.
A: Uphill (10 °)

The relationship between the tilting compensation and load spillage in the PZ auto tilt-in is as follows.

Relationship between the tilting compensation and load spillage

Relationship between the tilting compensation and load spillage
Setting Tilting compensation
DUMP side spillage TILT side spillage
OFF None Likely spilled Less likely spilled
Light Small ↑ ↑
↑ │ │
Normal │ │ │
↓ ↓ ↓
Heavy Large Less likely spilled Likely spilled

METHOD FOR PARKING MACHINE

k WARNING
• Stop the machine gradually. Avoid a sudden stop.
• Do not park the machine on a slope. If it is unavoida-
ble to park the machine on a slope, place the machine
at a right angle to the slope face, lower the bucket to
the ground, and then chock the tires to prevent the
machine from moving.
• The machine may move suddenly if the control lever is
touched by accident. This may lead to a serious per-
sonal injury or death. Before leaving the operator's
seat, always lock the work equipment (the pilot lamp in
the switch is lit).
• Even if the parking brake switch is turned on, there is
danger until the parking brake pilot lamp on the moni-
tor lights up. Keep depressing the brake pedal.

NOTICE
Never use the parking brake switch to brake the machine
when the machine is traveling except in an emergency.
Stop the machine, and then apply the parking brake.

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

pedal (2) to stop the machine.
The machine stops.

2. Set the directional lever (3) in NEUTRAL position (N).

3. Set the parking brake switch (4) to ON position (A) to apply

the parking brake.

4. Operate the multifunction mono-lever (5) to lower the

bucket.

5. Check that the multifunction mono-lever (5) is in “HOLD”

position.
6. Press the work equipment lock switch (6) and lock the
work equipment (the pilot lamp in the switch is lit).

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METHOD FOR CHECKING AFTER FINISHING WORK

CHECKS BEFORE STOPPING ENGINE
Check the engine coolant temperature, engine oil pressure, HST oil temperature, remaining fuel level, and re-
maining DEF level on the machine monitor.
If the engine has overheated, do not stop the engine abruptly. Run it at a medium speed to cool it down gradual-
ly before stopping.

CHECKS AFTER STOPPING ENGINE

1. Perform walk-around check for oil or coolant leakage and for abnormality in work equipment, exterior parts,
and undercarriage.
If oil or coolant leakage or any abnormality is detected, repair it.
2. Check DEF tank, pump, injector, hose, and joint for leakage.
If any abnormality is found, ask your Komatsu distributor for repair.
3. Fill the fuel tank.
4. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
5. Remove any mud affixed to the undercarriage.

LOCK
Position to be locked
Always lock the following places.
(1) Fuel tank filler cap
(2) Rear grille
(3) Engine side cover (2 places)
(4) Hydraulic tank oil filler cap
(5) Cab door
(6) Air conditioner fresh air filter cover
(7) DEF inspection cover
The starting switch key is a common key for (1) to (7).

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METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP

PROCEDURES FOR OPENING FUEL FILLER PORT CAP
1. Insert the starting switch key into the key slot.
2. Turn the starting switch key to “OPEN” position (A), and
then align the key slot with match mark (1) of the cap.
Position (A)
OPEN
Position (B)
LOCK
3. Open the oil filler cap.

PROCEDURES FOR LOCKING FUEL FILLER PORT CAP

1. Screw in the oil filler cap.
2. Insert the starting switch key into the key slot.
3. Turn the starting switch key to “LOCK” position (B), and
then align the key slot with match mark (1) of the cap.
Position (A)
OPEN
Position (B)
LOCK
4. Remove the starting switch key.

METHOD FOR OPENING AND CLOSING HYDRAULIC OIL FILLER PORT CAP
PROCEDURES FOR OPENING HYDRAULIC OIL FILLER PORT CAP
1. Remove the bolts (1) (2 pieces) and remove the cover (2).

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MACHINE OPERATIONS AND CONTROLS OPERATION

2. Insert the starting switch key into the key slot.

3. Turn the starting switch key to “OPEN” position (A), and
then align the key slot with the match mark (3) of the cap.
Position (A)
OPEN
Position (B)
LOCK
4. Turn the oil filler cap slowly to unlock it.
“Click” sound is heard.
5. Open the oil filler cap.

PROCEDURES FOR LOCKING HYDRAULIC OIL FILLER PORT CAP

1. Screw in the oil filler cap.
2. Insert the starting switch key into the key slot.
3. Turn the starting switch key to “LOCK” position (B).
Position (A)
OPEN
Position (B)
LOCK
4. Remove the starting switch key.
5. Install the cover (2) with bolt (1).

METHOD FOR OPENING AND CLOSING COVER WITH LOCK

METHOD FOR OPENING COVER WITH LOCK
1. Insert the key into the key slot.
2. Turn the key counterclockwise and open the cover by pull-
ing the cover handle.
Position (A): OPEN
Position (B): LOCK

METHOD FOR LOCKING COVER WITH LOCK

1. Close the cover and insert the key into the key slot.
2. Turn the key clockwise and remove it.

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HANDLE TIRE
PRECAUTIONS WHEN HANDLING TIRES
k CAUTION
If a tire reaches the using limit shown below, it may be
damaged and may cause an accident.
For safety, replace such a tire with a new one.
• Service limit for wear
• When the remaining depth of the grooves on con-
struction equipment tires (at a point approximately
1/4 of the tread width) is 15 % of the groove depth
on a new tire
• When an abnormal wear such as uneven wear or
stepped wear is found on a tire or when the cord
layer of a tire is exposed
• Service limit for damage
• When a damage or crack of a tire has reached the
cord
• When a damage on or dragging of cord is found
on a tire
• When tires are peeled (separated)
• When a damage is found in the bead of a tire
• When air leakage or an unrepairable damage is
found on a tubeless tire
• Do not install the tire protector (mesh chain) to rear
wheels.
• Do not to use tires, such as urethane tires, that weigh
remarkably more than the standard tires since the ma-
chine can be damaged due to an unexpected load.
• If a tire not specified by Komatsu is used, rim dis-
placement may occur between the tire and rim. Opera-
tor comfort may be degraded as well.

(1) Side wall

(2) Shoulder
(3) Tread
(4) Breaker or belt (cord layer)
(5) Bead
(6) Inner liner
(7) Cord
Contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking
due care.

TIRE PRESSURE
Check the tire inflation pressure before driving, when the tires are cool.
Excessively low tire inflation pressure induces overload on the tire, and excessively high pressure causes tire
cut (surface damage) and shock burst. To prevent these problems, adjust the tire inflation pressure referring to
the following table.

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Deflection ratio = (H - h)/Hx100

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 (boom horizontal): Approximately
15 to 25 %
When digging (rear wheels off ground): Approximately 25 to
35 %
In addition to the checking of tire inflation pressure, check for
small cuts and peeling on tires, for sticking of nails and metallic
pieces that may cause punctures, and for any abnormal wear.
Keep the working road surface constantly clean by removing fallen stones. This will extend the tire life and give
improved economy.
• For operations on normal road surfaces, rock digging operations: High end of range in the following table.
• Stock pile operations on soft ground: Average pressure in air pressure chart
• Operations on sand (operations not using much digging force): Low end of range in the following table
If the deflection of the tire is excessive, raise the inflation pressure within the limits given in the following table to
give a appropriate deflection (see deflection ratio).

H: Free Air pressure [ kPa { kg/cm2}]

Tire size
height Normal road
(Pattern) Ground (sandy When shipped
( mm) ground) Stock pile Digging from the plant

Front 425 425 425 425

20.5-R25☆ wheel {4.25} {4.25} {4.25} {4.25}
383
(L3: Rock) (ML) 400 400 400 400
Rear
wheel {4.0} {4.0} {4.0} {4.0}

Front 330
20.5-25-12PR wheel 190 to 330 190 to 330 210 to 350 {3.3}
386
(L2:Traction) (BS) {1.9 to 3.3} {1.9 to 3.39} {2.1 to 3.5} 280
Rear
wheel {2.8}

Front 330
20.5-25-12PR wheel 190 to 330 190 to 330 210 to 350 {3.3
387
(L3: Rock) (BS) {1.9 to 3.3} {1.9 to 3.3} {2.1 to 3.5} 280
Rear
wheel {2.8}

Stock pile operation means scooping and piling gravel.

PRECAUTIONS FOR LOAD-AND-CARRY OPERATION

When traveling continuously in load-and-carry operation, choose the appropriate tires to match the operating
conditions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged.
Consult your Komatsu distributor or tire dealer.

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HANDLE AIR CONDITIONER

NOTICE
• To prevent putting any excessive load on the engine or compressor, use the air conditioner only
when the engine is running.
• When running in the air conditioner, always start with the engine running at low speed. Never start
the air conditioner when the engine is running at high speed.
It will cause failure of the air conditioner.
• If water gets into the control panel or sunlight sensor, it may lead to unexpected failure, take care
not to let water get on these parts.
In addition, never bring any open flame near them.
• For the auto function of the air conditioner to work properly, always keep the sunlight sensor clean
and do not leave anything around the sunlight sensor that may interfere with its sensor function.
• Where there is dust or bad smell in the using environment of the machine, use the RECIRC mode.
• When turning the cooling on, if the temperature inside the cab is high, open the doors and windows to bring
in fresh air before using the air conditioner.
• When performing inspection and maintenance of the machine equipped with the air conditioner, refer to the
tables in “METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER (4-37)”.
• To allow the air conditioner to show its full performance, have inspection and maintenance performed peri-
odically. When adding refrigerant or performing other maintenance, special tools and instruments are nee-
ded, so ask your Komatsu distributor to perform inspection and maintenance.
• When the air conditioner is not used every day, to prevent loss of the film of oil at various parts, run the air
conditioner with the engine at low speed from time to time and perform cooling or dry heating for several
minutes.
• To prevent leakage of the refrigerant from the air conditioner cooling circuit, operate the air conditioner for
several minutes 2 or 3 times a month during the off-season. If the air conditioner is left for a long time when
the refrigerant is leaking, internal rust may occur, causing failure.
• When the temperature inside the cab is low, the air conditioner may not work. In this case, circulate recircu-
lation air to warm the inside of the cab. After that, turn the air conditioner switch ON, the air conditioner will
work.
• If any abnormality is detected in any equipment or sensor used on the air conditioner, the air conditioner
system caution lamp lights up on the monitor screen. If the air conditioner system caution lamp lights up,
ask your Komatsu distributor for inspection and repair.
Ventilation
• When running the air conditioner for a long time, turn the lever to FRESH position once an hour to perform
ventilation and cooling.
• If you smoke when the air conditioner is on, the smoke may hurt your eyes. In such case, open the window
and turn the lever to FRESH for a while for ventilation and cooling to drive smoke out.
Temperature control
For reasons of health, the optimum setting for cooling is considered to be when it feels slightly cool (5 to 6 °C
lower than the ambient temperature) when you enter the cab.
Be careful to select the appropriate temperature.

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EXPLANATION OF AIR CONDITIONER EQUIPMENT

(1) OFF switch (6) FRESH/RECIRC air selector switch

(2) Auto switch (7) Vent selector switch
(3) Air conditioner switch (8) Defroster switch
(4) Fan switch (9) Display monitor
(5) Temperature control switch
Air conditioner monitor
(A) Air flow bar (E) Vent display
(B) Air conditioner operation symbol (F) Automatic operation symbol
(C) Set temperature display (G) Defroster symbol
(D) FRESH/RECIRC selector symbol

OFF SWITCH
The OFF switch is used for stopping the fan and air conditioner.
REMARK
Even if this OFF switch is pressed, the monitor screen does not
switch to the air conditioner adjustment screen.

FAN SWITCH
Use the fan switch to adjust the air flow from the fan in the
manual operation.
When switch (A) is pressed while the air conditioner power
supply is OFF, the electric power for the air conditioner is
turned ON. At this time the air flow starts from “LOW”.
• The air flow can be adjusted to 6 levels.
• Press switch (A) to increase the air flow and press switch
(B) to decrease the air flow.

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OPERATION HANDLE AIR CONDITIONER

• During auto operation, the air flow is automatically adjusted.

The set position of the air flow is indicated on the display monitor.
Monitor display Air flow

Air flow “LOW”

Air flow “MEDIUM 1”

Air flow “MEDIUM 2”

Air flow “MEDIUM 3”

Air flow “MEDIUM 4”

Air flow “HIGH”

TEMPERATURE CONTROL SWITCH

Use the temperature control switch to adjust the temperature
inside the cab. The temperature can be set between 18 to
32 °C.
• Press the △ switch to raise the set temperature; press the
▽ switch to lower the set temperature.
The set temperature is indicated on the display monitor.
• The temperature is generally set at 25 °C.
• The temperature can be set in stages of 0.5 °C.

Monitor display and function

Monitor display Set temperature
18 °C Max. cooling
18.5 to 31.5 °C Adjusts temperature inside cab to set temperature
32 °C Max. heating

REMARK
If the mode is set to auto mode and the temperature setting is set to 18 °C or 32 °C, the air flow from the fan is
always set to “HIGH” and does not change even when the temperature reaches the set temperature.

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VENT SELECTOR SWITCH

In the manual operation, use the vent selector switch to select
the vents.

• There are 4 modes of vents: FACE, FACE/FOOT, FOOT,

and FOOT/DEF. (DEF is selected only when the defroster
switch is pressed.)
• When the switch is pressed, the display on the display
monitor switches in order and air blows out from the vents
displayed.
• When this switch is pressed in the defroster mode, the
vents right before being switched to DEF is selected.
• During automatic operation, the vents are automatically
selected.
(A): FACE (2 places)
(B): FOOT (2 places)
(C): DEF (2 places)
(D): DEF (2 places)
Vent
Monitor display Vent mode Remarks
(A) (B) (C) (D)

Face vent ○ -

Face and foot vents ○ ○ -

Foot vent ○ -

Foot and defroster vents ○ ○ ○ -

Cannot be selected for auto-

Defroster vent ○ ○
matic operation

Air blows out from the vents marked with ○.

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OPERATION HANDLE AIR CONDITIONER

AUTO SWITCH
Use auto switch for automatic selection of the air flow and
vents according to the set temperature.
This switch is also used as the main switch of the air condition-
er.
• When AUTO switch is pressed, AUTO on the display moni-
tor lights up to indicate that the air conditioner is in the au-
tomatic mode.
• When switching from automatic operation to manual oper-
ation, it is possible to use the switches to select the air flow
and vents.
At this time, AUTO on the display monitor goes out.
• When clearing the window mist at low temperature, use
the defroster switch.
REMARK
Do not leave the door open for a long time (3 minutes or lon-
ger) while air conditioner is working.
The automatic air conditioner controls the air automatically ac-
cording to the environment.
If the environment changed suddenly by leaving cab door open
for a long time, etc., the control of air conditioner may change
temporarily, but this is not a failure.
Even if the control changes, it returns automatically to control
the air according to the environment after certain period of time
elapses.

FRESH/RECIRC AIR SELECTOR SWITCH

Use FRESH/RECIRC air selector switch to switch the air
source between recirculation of the air inside the cab and in-
take of fresh air from the outside.
• In the fresh air mode, (A) is lit on the display monitor.
• In the recirculation air mode, (B) is lit on the display moni-
tor.

RECIRC
• Only the air inside the cab is circulated. Use this setting to
perform quick cooling or heating of the cab or when out-
side air is dirty.
FRESH
• Outside air is taken into the cab. Use this position to make
the air inside the cab fresh or to remove the mist from the
cab windows.

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HANDLE AIR CONDITIONER OPERATION

DISPLAY MONITOR
The display monitor displays the state of air flow (A), operation
of air conditioner (B), set temperature (C), FRESH/RECIRC air
(D), vents (E), automatic operation (F), and defroster (G).

AIR CONDITIONER SWITCH

Use the air conditioner switch to start and stop the cooling,
heating, or drying function.
• When the air conditioner switch is pressed while the main
power switch is turned ON, the air conditioner is turned ON
and the air conditioner operation symbol is indicated on
the display monitor.
• If the switch is pressed again, it is turned OFF and the op-
eration symbol on the display monitor goes out.

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OPERATION HANDLE AIR CONDITIONER

DEFROSTER SWITCH
The defroster switch is used to set the vents in the defroster
mode.
• Use this mode to clear the front glass mist, etc.
• When the defroster switch is pressed during automatic op-
eration, AUTO on the air conditioner monitor goes out and
the defroster mark is displayed.

SUNLIGHT SENSOR
Sunlight sensor automatically adjusts the flow of air from the
vents to match the strength of the sun's rays. (Only in automat-
ic operation mode)
In addition, it automatically detects changes in the temperature
inside the cab caused by changes in the strength of the sun's
rays beforehand and automatically adjusts the temperature.

METHOD FOR OPERATING AIR CONDITIONER

The air conditioner can be operated automatically or manually. Select the method of operation as desired.

METHOD FOR AUTOMATIC OPERATION

1. Turn the auto switch ON.
AUTO lights up on the display monitor.

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HANDLE AIR CONDITIONER OPERATION

2. Press (A) or (B) of the temperature control switch to set to

the desired temperature.
The air flow and combination of the vents are automatically
selected according to the set temperature, and the air con-
ditioner is operated automatically to provide the set tem-
perature.
REMARK
• If the air conditioner switch is not turned ON when the
ambient temperature is high, air is not cooled and its
temperature may not decrease to the set temperature.
• After automatic operation, the air flow may be set to
“Lo” for a certain period to prevent cold air from blow-
ing out, depending on the ambient temperature.
• Once the desired temperature is set, do not operate
the temperature control switch unnecessarily. It may
take longer time to reach the set temperature.
• To heat or cool air quickly, set the temperature display
to 18.0 °C (max. cooling) or 32.0 °C (max. heating).
• If any switch is operated during automatic operation,
the function of that switch is applied first, and AUTO
on the air conditioner monitor goes out and the man-
ual operation is selected.

METHOD FOR STOPPING AUTOMATIC OPERATION

Press the air conditioner OFF switch.
The display on the display monitor goes out and the operation
stops.

METHOD FOR MANUAL OPERATION

1. Press (A) or (B) of the fan switch and adjust the air flow.
If fan switch (A) is pressed while the air conditioner power
supply is OFF, the air conditioner power supply is turned
ON and the air flow is set to “Lo”.

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OPERATION HANDLE AIR CONDITIONER

2. Turn the air conditioner switch ON.

At this time, the air conditioner operation mark lights up on
the display monitor.

3. Press (A) or (B) of the temperature control switch to adjust

the temperature in the cab.
REMARK
The air temperature is so adjusted that the temperature in
the cab becomes the set temperature when the set tem-
perature display is 18.5 °C to 31.5 °C, even in the manual
operation.
To heat or cool the air quickly, set the temperature display
to 18.0 °C (max. cooling) or 32.0 °C (max. heating).

4. Press vent selector switch and select the desired vents.

At this time, the display for the vent of the display monitor
changes according to the selection.

5. Press the FRESH/RECIRC air selector switch and select

recirculation of the air inside the cab (RECIRC) or intake of
fresh air from outside (FRESH).
REMARK
• To heat or cool the air quickly, set the temperature dis-
play to 18.0 °C (max. cooling) or 32.0 °C (max. heat-
ing).
• To select the automatic operation during manual oper-
ation, press the AUTO switch.

METHOD FOR STOPPING MANUAL OPERATION

Press the air conditioner OFF switch.
The display on the display monitor goes out and the operation
stops.

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HANDLE AIR CONDITIONER OPERATION

METHOD FOR OPERATING DEFROSTER

Frost adhered to the outside of the window glass can be removed by defroster operation.
1. Press the defroster switch to set the vents in DEF mode.

2. Press FRESH/RECIRC air selector switch and set it to RE-

CIRC mode.

3. Press the temperature control switch and set the tempera-

ture to 32.0 °C.
To remove frost quickly, press the fan switch and set the
air flow to “Hi”.

METHOD FOR OPERATING DEMIST

Dew condensation adhered to the inside of the window glass can be removed by demist operation.
1. Press the defroster switch to set the vents in DEF mode.
2. Press air conditioner switch and perform the cooling or dry
heating operation.
To remove the dew condensation quickly, press the fan
switch to set the air flow to “Hi”.
REMARK
Do not decrease the set temperature too much during the
demist operation. If cold air blows against the front window
glass, the outside of the glass mists and that may lower
the visibility.

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OPERATION TRANSPORTATION

TRANSPORTATION
TRANSPORTATION PROCEDURE
When transporting the machine, choose the transportation method in reference to the weight and dimensions of
machine.
Note that the “SPECIFICATIONS” (weight and dimensions) vary depending on the type of tire and bucket.

LOADING AND UNLOADING WITH TRAILER

k WARNING
• When loading or unloading the machine, run the engine at a low speed and operate the machine
slowly in low travel speed.
• Select a flat and firm ground when loading or unloading the machine.
Maintain a safe distance from the road shoulder
• Use ramps with ample width, length, thickness, and strength and install them with a maximum slope
of 15 °.
When using piled soil, compact the piled soil fully to prevent the slope face from collapsing.
• Remove mud from the undercarriage of the machine so that the machine will not slip sideways on
the ramps.
In addition, remove water, snow, ice, grease, oil, etc. from the ramps.
• Never correct your steering on the ramps. There is danger that the machine may tip over.
If it is necessary to change the travel direction, return to the ground or to the bed of the trailer, then
change the travel direction.
• The center of gravity of the machine shifts suddenly at the joint of the ramps and the trailer, so
there is a danger of the machine losing its balance. Accordingly, pass this point slowly.

When loading or unloading, always use ramps or a platform. Proceed as follows.

PROCEDURES FOR LOADING MACHINE

Load on a firm and level ground.
Maintain a safe distance from the road shoulder
1. Apply the brake of the trailer securely.
2. Set chocks (1) to the front and rear of the tires to secure
the trailer.
3. Set right and left ramps (2) parallel to each other and
equally spaced to the right and left of center (3) of the trail-
er. Make angle of installation (4) a maximum of 15 °.
If the ramps bend a large amount under the weight of the
machine, put blocks (5) under the ramps to prevent them
from bending.
4. Set the travel direction toward the ramps and drive slowly
for loading.
5. Load the machine correctly in the specified position on the trailer.

METHOD FOR SECURING MACHINE

After loading the machine onto a trailer, secure the machine as follows.
1. Lower the work equipment gently.
2. Check that the multifunction mono-lever is in “HOLD” position.

3-223
TRANSPORTATION OPERATION

3. Press the work equipment lock switch (1) and lock the
work equipment (the pilot lamp in the switch is lit).

4. Move the parking brake switch (3) from OFF position (B) to
ON position (A), with the brake pedal (2) depressed, to ap-
ply the parking brake securely.
Check that the machine is stopped completely.
5. Turn the starting switch to OFF position and stop the en-
gine.
Remove the key from the starting switch.

6. Set the frame lock bar to LOCK position (L) to lock the
front and rear frames.
7. Set chocks at the front and rear of the tires to prevent the
machine from moving during transportation.

8. Tie one end of each chain or wire rope of appropriate strength to the tie-down holes as shown in the figure,
and secure the machine.
Secure the machine so that it will not move during transportation.
In particular, fix the machine securely to prevent it from slipping sideways.
Keep the securing tools off the machine.
9. Stow the antenna, etc.

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OPERATION TRANSPORTATION

Securing position

Fixing angle
(A) : 70 °
(B) : 57 °
(C) : 34 °
(D) : 47 °
Expected trailer width
(E) : 2990 mm

3-225
TRANSPORTATION OPERATION

The fixed load per 1 piece

Front frame: 126000 N {12850 kg} 
Rear frame: 94000 N {9590 kg} 

REMARK
When putting the chains or wire ropes to the tie down hole, you
may open the engine side cover (4) to perform the work.

PROCEDURES FOR UNLOADING MACHINE

Perform unloading of the machine on a firm, level ground.
Maintain a safe distance from the road shoulder
1. Apply the brake of the trailer securely.
2. Set the chocks (1) to the front and rear of the tires to se-
cure the trailer.
3. Set the right and left ramps (2) parallel to each other and
equally spaced to the right and left of center (3) of the trail-
er. Make the installation angle (4) at maximum of 15 °.
If the ramps bend a large amount under the weight of the
machine, put blocks (5) under the ramps to prevent them
from bending.
4. Remove the chains and wire ropes fastening the machine.
5. Set the frame lock bar to FREE position (F).
6. Start the engine.
Warm up the engine fully in cold weather.

3-226
OPERATION TRANSPORTATION

7. Check that the multifunction mono-lever is in “HOLD” posi-

tion.
8. Press the work equipment lock switch (6) and unlock the
work equipment lock (the pilot lamp in the switch is not lit).

9. Set the parking brake switch to OFF position (B) to release

the parking brake.
10. Set the travel direction toward the ramps and drive slowly
to unload the machine.

METHOD FOR LIFTING MACHINE

k WARNING
• The person using the crane to perform lifting operations must be a qualified crane operator.
• Never raise the machine with any worker on it.
• Always use a wire rope that has ample strength for the weight of the machine.
• When lifting, keep the machine horizontal.
• When performing lifting operations, do as follows to prevent the machine from moving unexpected-
ly.
Set the parking brake switch to “ON” position.
Lock the work equipment (the pilot lamp in the switch is lit).
Set the frame lock bar to the “LOCK” position.
• Never enter the area under or around a lifted machine.
• There is a danger of the machine losing its balance.
Use the procedure below to set the machine in the proper posture and use the sling when lifting the
machine.

NOTICE
This method of lifting applies to the standard specification machine.
The method of lifting differs depending on the attachments and options installed.
For details of the procedure for machines that are not the standard specification, consult your Komatsu
distributor.
For the weight, see “SPECIFICATIONS (5-2)”.
Lifting work is allowed for only machines having lifting marks.
Before starting the lifting work, place the machine on a level ground and perform the following.

3-227
TRANSPORTATION OPERATION

1. Start the engine.

2. Set the machine horizontally and set the work equipment
in the travel posture.
See “METHOD FOR STARTING MACHINE (TRAVEL
FORWARD AND REVERSE, AND SHIFTING GEAR) AND
STOPPING MACHINE (3-184)”.
(A): 30 cm

3. Check that the multifunction mono-lever is in “HOLD” posi-

tion.
4. Press the work equipment lock switch (1) and lock the
work equipment (the pilot lamp in the switch is lit).
5. Stop the engine.

6. Check the safety around the operator's compartment, set

the frame lock bar to LOCK position (L) in order to prevent
the front frame and rear frame from articulating.

7. Use the lifting tools such as the wire rope and sling suita-
ble for the weight of the machine as shown in the figure of
the lifting position. Extend the wire rope and fix the ma-
chine.
NOTICE
• Use protectors, etc. so that the wire ropes will not
be broken at sharp edges or narrow places.
• Width of the threader and bar must be sufficient
for preventing the lifting equipment and wire rope
from contacting the machine.
• Remove the rear full-length fender before lifting a
machine if the machine is equipped with the rear
full-length fender.
8. Just before lifting up the machine, set the slings, and lift the machine 100 to 200 mm off the ground with the
sling first. Check that the wire ropes are not slack and the machine is level, then lift it up slowly.

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OPERATION COLD WEATHER OPERATION

COLD WEATHER OPERATION

COLD WEATHER OPERATION INFORMATION
If the ambient temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze.
Follow the instructions described as follows.

FUEL AND LUBRICANTS

Change fuel and oil with ones of low viscosity for all components.
For the details of specified viscosity, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)”.

COOLANT
k WARNING
• Coolant 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 amount of fresh water and see a doctor immediately.
• When handling the cooling water containing coolant that has been drained during changing the
coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to
perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the
ground surface.

NOTICE
Komatsu recommends using Non-Amine Engine Coolant (AF-NAC) for the coolant.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
For details on the coolant change interval and the density of Non-Amine Engine Coolant (AF-NAC), see “METH-
OD FOR CLEANING INSIDE OF COOLING SYSTEM (4-21)”.

DEF
NOTICE
• DEF freezes at –11 °C.
If DEF in DEF tank freezes, it may expand to break the devices in the tank. The parts inside the tank
may be affected. Add DEF to the specified amount for cold weather (below the level of when DEF
may freeze).
For the specified amount of DEF, see “METHOD FOR CHECKING DEF LEVEL AND ADDING DEF
(3-159)”.
• If DEF or the machine equipped with DEF system cannot be stored when the outside temperature is
lower than –11 °C, DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF,
and keep it in the condition free from freezing.

BATTERY
k WARNING
• Battery generates flammable gas. Never bring any open flame near fuel.
• Battery electrolyte is dangerous object. If it gets in your eyes or on your skin, wash it off with a
large amount of water and consult a doctor.
• Battery electrolyte dissolves paint. If it gets on 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 pow-
er source. There is danger that the battery may explode.
• Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground sur-
face.

3-229
COLD WEATHER OPERATION OPERATION

When the ambient temperature drops, the capacity of the battery will also drop. Maintain the battery charging
rate as close as possible to 100%. Insulate it against cold temperature to ensure that the machine can be star-
ted easily in the next morning.
REMARK
Measure the gravity of the electrolyte and calculate the charging rate from the following conversion table.
Electrolyte Temper-
ature 20 °C 0 °C –10 °C –20 °C
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

• When the ambient temperature is low, the capacity of the battery considerably drops. Cover it, or remove it
from the machine to place it in the warm place. Restore it again before the operation.
• If the electrolyte level is low, add distilled water in the morning before beginning the work. Do not add water
after the day's work to prevent diluted electrolyte in the battery from freezing during the night.

PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, observe the following precautions.
• Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean
to prevent damage to the seal caused by mud, dirt, or drops of water on the rod from getting inside the seal.
• Place the machine on a firm, dry ground.
If this is impossible, park the machine on boards.
The boards prevent the tracks from freezing to the ground, and allow the machine to move the next morn-
ing.
• Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
• Fill up the fuel tank. This minimizes moisture condensation in the tank when the temperature drops.
• In cold weather condition, add DEF to the defined level strictly. If adding more than the defined level, it may
expand to break the devices in the tank when it freezes.
If DEF tank level is lower than the defined level for the cold weather, DEF may freeze easily to damage the
parts in DEF system. If the filler cap freezes, defreeze and open.

PRECAUTIONS IN COLD WEATHER

If engine has run at idle for a long time or machine is traveling at 3rd or 4th speed in cold weather, inside of
KCCV and KCCV drain piping may freeze and be plugged.
To avoid such long idling of the engine, stop the engine or, if it is necessary to run the engine at idle, apply a
load from time to time.
Also, automatic fan reverse is useful to keep engine room warm and prevent inside of KCCV and KCCV drain
piping from freezing. Set the automatic fan reverse mode to “mode C” according to “RADIATOR FAN AUTO-
MATIC REVERSE MODE (3-61)”.

AFTER COLD WEATHER SEASON

When the season changes and the weather becomes warmer, do as follows.
Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “METHOD
FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by repeated
freeze, ask your Komatsu distributor to inspect.

3-230
OPERATION PRECAUTIONS FOR LONG-TERM STORAGE

PRECAUTIONS FOR LONG-TERM STORAGE

PREPARATION FOR LONG-TERM STORAGE
When putting the machine in storage for a long time (more than one month), do as follows.
• Clean and wash all parts of the machine and store it indoors. If the machine has to be stored outdoors,
select a level ground and cover the machine with waterproof sheet.
• Fill up the fuel tank. This prevents dew condensation.
• Grease the machine and change the oil before storage.
• Fill up DEF tank (Except cold weather condition).
If the inside dries up, urea is deposited and it may cause failures in component operation.
• Coat the exposed portion of the hydraulic cylinder piston rod with grease.
• After turning the starting switch to OFF position, check that the system operating lamp is not lit. Then set
the battery disconnect switch to OFF position and remove the key. When storing the battery, cover it.
For the operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-119)”.
• Lock the work equipment (the pilot lamp in the switch lights up).
• To prevent rust, fill the cooling circuit with Non-Amine Engine Coolant (AF-NAC) to give a density of at least
30% for the engine coolant.

MAINTENANCE DURING LONG-TERM STORAGE

k WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors
and windows to improve ventilation and prevent gas poisoning.

• During storage, operate and move the machine for a short distance once a month so that a new film of oil
will coat moving parts. At the same time, charge the battery as well.
• When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
• If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a
month to lubricate all parts of the air conditioner compressor. Always run the engine at low idle when doing
this. In addition, check the refrigerant level twice a year.

STARTING MACHINE AFTER LONG-TERM STORAGE

NOTICE
If the machine has been stored without performing the monthly rust-prevention operation, consult your
Komatsu distributor before using it.
When using the machine after long-term storage, perform the following items before using it.
• Wipe off the grease from the hydraulic cylinder rods.
• Add oil and grease at all lubrication points.
• When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before
and after starting the engine. If there is water in the oil, change all the oil.
• Check for rust on engine pulley and abnormality on belt.
If the surface of pulley where contacting with the belt is covered with too much rust, remove them with wire
brush.
• Insert the battery disconnect switch key and turn it to ON position.
• If the machine is stored for a long period with the battery disconnect switch OFF or the battery terminal dis-
connected, the clock information may be lost. In this case, set the information again. For detail, see
“CLOCK ADJUSTMENT”.
• If the machine has been stored for more than 2 months, perform the following procedure.

3-231
PRECAUTIONS FOR LONG-TERM STORAGE OPERATION

• Before starting the engine, replace DEF filter and fill up DEF tank according to the procedure in
“METHOD FOR REPLACING DEF FILTER”.
• Start the engine and check correctly.
If SCR system has any abnormality, warning is displayed on the monitor screen and the audible alert
sounds. If SCR system has any abnormality, stop the engine, and then start it again.
If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor.
• If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement.
Dispose of drained DEF according to the local regulations and rules.
Aged DEF may have smell of ammonia. Replace DEF in a well-ventilated place and take care not to
inhale its vapor.

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OPERATION TROUBLES AND ACTIONS

TROUBLES AND ACTIONS

ACTIONS WHEN RUNNING OUT OF FUEL
k WARNING
When starting the engine again, check safety around the engine thoroughly, and then crank the engine.

When starting the engine again after running out of fuel, fill with fuel, and bleed the air from the fuel system
before starting the engine.

PROCEDURES FOR BLEEDING AIR FROM FUEL CIRCUIT

1. Open the engine side cover (1) on the right side of the ma-
chine.

2. Loosen the knob of feed pump (2), pull it out, then pump it
in and out until the movement becomes heavy.
REMARK
Air may remain inside of the water separator, however, the
engine can be started after pumping the feed pump (2) in
and out until it becomes heavy. Leave it as it is for a while
after stopping the engine, and air is bled spontaneously.
3. Push in and tighten the knob of feed pump (2).
4. Close the engine side cover (1) on the right side of the ma-
chine.

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TROUBLES AND ACTIONS OPERATION

PRECAUTIONS FOR TOWING MACHINE

k WARNING
Use the correct towing equipment and towing method. Any
mistake in the selection of the wire rope or drawbar or the
method of towing a disabled machine and being towed
may lead to serious personal injury or death.
• Always confirm that the wire rope or drawbar used for
towing has ample strength for the weight of the ma-
chine being towed.
• Never use a wire rope which has breaks in strands (A),
reduced diameter (B), or kinks (C). There is a danger
that the rope may break during the towing operation.
• Wear the leather gloves always when handling the wire
ropes.
• Never tow a machine on a slope.
• During the towing operation, never stand between the
towing machine and the machine being towed.
• Operate the machine slowly and be careful not to ap-
ply any sudden load to the wire rope.
• If there is a failure in the brake system, the brakes will
not work, so be extremely careful.

NOTICE
• Tow the machine only for a short distance, such as to a place for inspection and maintenance.
Do not tow the machine for a long distance.
• For the allowable towing capacity for this machine, see “SPECIFICATIONS (5-2)”.
• For the procedure for towing a disabled machine, consult your Komatsu distributor.
This machine must not be towed except in emergencies. However, if it is avoidable to tow the machine, take the
following precautions.
• When releasing the brake, secure the machine with chocks. If the wheels are not chocked, the machine
may move suddenly.
• 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 performed.
This method is applied only in an emergency. If the machine must be moved a long distance, use a trans-
porter.
• If it is impossible to operate the steering and brakes of the machine being towed, do not let anyone ride on
the machine.
• Keep the angle of the towing rope as small as possible. Keep the angle between the center lines of the 2
machines to within 30 °.
• Usually, use a towing machine of the same class as the machine being towed. Check that both towing ma-
chine and towed machine have ample braking power, and rim pull to allow them to control both machines
on slopes or on the tow road.
• When towing a machine downhill, it may be necessary to connect another machine to the rear of the towed
machine in order to provide ample rim pull and breaking power. The controllability of the machines can be
secured by this method.
• Towing may be performed under various conditions, so it is impossible to determine beforehand the re-
quired traction force. Towing on flat level roads will require the minimum rim pull, while towing on slopes or
on uneven road surfaces will require the maximum rim pull.
• Connect a wire rope to the part indicated with the arrow in the drawing.

3-234
OPERATION TROUBLES AND ACTIONS

For the towing pin, see “METHOD OF USING TOWING

PIN (3-118)”.

TOW THE MACHINE WHOSE ENGINE CAN BE STARTED

• 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 get on the machine being towed and operate the steering in the direction that the ma-
chine is towed.

WHEN IT IS IMPOSSIBLE TO TRAVEL WHILE ENGINE IS RUNNING

Perform the following when it is impossible to travel while the engine is running.
1. Loosen the plug (1) under the HST pump until it touches
the stopper (2).
By doing so, the HST pump circuit is bypassed and the
travel is enabled.

3-235
TROUBLES AND ACTIONS OPERATION

2. Set the parking brake switch (3) to OFF position (B) to re-
lease the parking brake.
REMARK
If the parking brake is not released, see “METHOD FOR
RELEASING PARKING BRAKE”, and release the parking
brake.

TOW THE MACHINE WHOSE ENGINE CANNOT BE STARTED

When towing the machine with the engine stopped, observe the following procedures.
1. The transfer oil does not lubricate the system, so remove the front and rear drive shafts. If necessary, chock
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 performing towing operations, use 2 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 chocks from the tires and tow the machine.

METHOD FOR RELEASING PARKING BRAKE

k WARNING
• When releasing the parking brake, stop the machine on a level ground and check that the surround-
ing area is safe. If it is necessary to release the brake on a slope in an emergency, chock the tires
before starting the work.
• When the parking brake is released, the brake is not applied. When moving the machine, be careful
with the safety.

1. Remove the plugs (1) from the rear of transfer case.

2. Remove the bolt (2).

3. Insert the bolts (2) into the holes after the plugs (1) are re-
moved. Screw them in until they stop evenly.
The parking brake is released.
(A): Plug mounting hole (M14: O-ring boss)
(B): Releasing screw hole (M10)

3-236
OPERATION TROUBLES AND ACTIONS

METHOD FOR OPERATING MACHINE IN EMERGENCY

The speed range is selected by electric signals in normal operation. If there should be a failure in the electrical
system, and the machine does not move, ask your Komatsu distributor.
The machine may be able to travel temporarily by operating the emergency HST pump drive switch when the
machine has a trouble. If it is necessary to move the machine to a safe place urgently, move the machine with
the emergency HST pump drive switch.
NOTICE
If there should be a failure in the electrical system, and the machine does not move, ask your Komatsu
distributor.

PRECAUTIONS FOR DISCHARGED BATTERY

k WARNING
• It is dangerous to charge a battery when installed on a
machine. Make sure that it is removed before charg-
ing.
• When checking or handling the battery, stop the en-
gine and turn the starting switch and battery discon-
nect switch keys to OFF positions.
• The battery generates hydrogen gas, and it is danger-
ous that it may explode. Do not bring open flame such
as lighted cigarettes near the battery, or do nothing
that will cause sparks.
• Battery electrolyte is dilute sulfuric acid, and it will at-
tack your clothes and skin. If it gets on your clothes or
on your skin, immediately wash it off with a large
amount of clean water.
If it gets in your eyes, wash the eyes immediately with
clean water, then consult a doctor for medical treat-
ment.
• When handling batteries, always wear protective eye-
glasses and rubber gloves.
• When removing the battery, first disconnect the cable
from the ground (normally the negative (-) terminal).
When installing, first connect the cable to the positive
(+) terminal.
If a tool touches the positive terminal and the chassis,
it is dangerous that it may cause a spark. Be extremely
careful.
• If the terminals are loose, it is dangerous that the de-
fective contact may generate sparks, and it may cause
an explosion.
Install the cable terminals securely.
• When removing or installing the cable terminals,
check which is the positive (+) terminal and which is
the negative (-) terminal.

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TROUBLES AND ACTIONS OPERATION

PRECAUTIONS FOR REMOVING AND INSTALLING BATTERY

1. Before removing battery, remove the ground cable (nor-
mally connected to the negative (-) terminal).
If any tool touches the positive terminal of the battery and
the chassis, there is a danger that it will cause a spark.
Loosen the nuts of the terminal and remove the wires from
the battery.
2. When replacing the battery, fix the battery body with the
battery mounting fixtures.
Tightening torque
Nut (A): 1.77 to 2.16 Nm {0.18 to 0.22 kgm}
Nut (B): 17.7 to 27.5 Nm {1.8 to 2.8 kgm}
3. When installing the battery, connect the ground cable last.
Insert the hole of the terminal on the battery and tighten the nut.
Tightening torque: 9.8 to 11.8 Nm {1.0 to 1.2 kgm}
REMARK
The batteries are on both sides at the rear of the machine. The ground wire side battery is on the right side of
the machine.

PRECAUTIONS FOR CHARGING BATTERY

k WARNING
When charging the battery, if the battery is not handled
correctly, it is dangerous that the battery may explode. Al-
ways follow the instruction manual accompanying the
charger, and observe the following.
• Set the voltage of the charger to match the voltage of
the battery to be charged. If the correct voltage is not
selected, the charger may overheat and cause an ex-
,&
plosion.
• Connect the positive (+) charger clip of the charger to
the positive (+) terminal of the battery, then connect
the negative (-) charger clip of the charger to the nega-
tive (-) terminal of the battery. Be sure to attach the
clips securely.
• Set the charging current to 1/10 of the value of the rat-
ed battery capacity; when performing rapid charging,
set it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will
leak or the battery cells will 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. It is dangerous that this may ignite the battery
electrolyte and cause the battery to explode.
• Do not use or charge the battery if the battery electro-
lyte level is below LOWER LEVEL line. This may cause
an explosion. Check the battery electrolyte level peri-
odically and add the purified water (such as a commer-
cial battery fluid) to bring the electrolyte level to UP-
PER LEVEL line.

3-238
OPERATION TROUBLES AND ACTIONS

START ENGINE WITH JUMPER CABLES

k WARNING
• Never connect the positive (+) and negative (-) termi-
nals when connecting the cables.
• Wear the protective eyeglasses and rubber gloves al-
ways when starting the engine by using the jumper ca-
ble.
• Do not bring the normal machine into contact with the
failed machine.
The sparks caused near the battery could ignite the
hydrogen gas generated from the battery, so be care-
ful not to let it happen.
• Make sure that there is no mistake in the jumper cable
connections. When the final connection of the cables
is done to the engine block of the failed machine,
sparks will be generated. So, connect to a place as far
as possible from the battery.
• When disconnecting the jumper cable, take care not to
bring the clips in contact with each other or with the
machine.
• Never start the engine by short-circuiting the starting
motor (jump start).

NOTICE
• Use the jumper cables and clips that corresponds the battery size.
• The battery of the normal machine must be the same capacity as that of the failed machine.
• Check the cables and clips for damage or corrosion.
• Make sure that the cables and clips are firmly connected.
• Check that the work equipments of both machines are locked (the pilot lamps are lit) or the parking
brake switches are in LOCK position.
• Check that each lever is in NEUTRAL position.
• To prevent damage of the electric devices of the failed machine, turn the starting switch of the failed
machine to OFF position, check that the system operating lamp is not lit, and then turn the battery
disconnect switch key to OFF position and remove it before connecting the jumper cable.
For the operating method of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH
(3-119)”.

PROCEDURE FOR CONNECTING JUMPER CABLES

Turn the starting switch and battery disconnect switch of the failed machine, and the starting switch of the nor-
mal machine to OFF position.
1. Connect the clip of jumper cable (A) to the positive (+) ter-
minal of battery (C) on the failed machine.
2. Connect the clip at the other end of jumper cable (A) to the
positive (+) terminal of battery (D) on the normal machine.
3. Connect the clip of jumper cable (B) to the negative (-) ter-
minal of battery (D) on the normal machine.
4. Turn the battery disconnect switch (S) of the failed ma-
chine to ON position.
5. Connect the clip at the other end of jumper cable (B) to en-
gine block (E) of the failed machine.

3-239
TROUBLES AND ACTIONS OPERATION

METHOD FOR STARTING ENGINE

k WARNING
Check both of normal machine and failed machine that the lock lever is set to LOCK position (the pilot
lamp in the switch lights up). Check also that all the control levers are in NEUTRAL position.

1. Make sure the clips are firmly connected to the battery terminals.
2. Start the engine of the normal machine and run it at high idle (max. speed).
3. Turn the starting switch of the failed machine to START position and start the engine.
If the engine does not start, try it again after 2 minutes or more.

PROCEDURE FOR DISCONNECTING JUMPER CABLES

After the engine has started, disconnect the jumper cables in the reverse of the order in which they were con-
nected.
1. Remove the clip of jumper cable (B) from engine block (E)
on the failed machine.
2. Remove the clip of jumper cable (B) from the negative (-)
terminal of battery (D) on the normal machine.
3. Remove the clip of jumper cable (A) from the positive (+)
terminal of battery (D) on the normal machine.
4. Remove the clip of jumper cable (A) from the positive (+)
terminal of battery (C) on the failed machine.

OTHER TROUBLE
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM
• For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor.
• In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Problem Main causes Remedy
Defective wiring Check and repair loose terminals,
Lamp does not glow brightly even open circuit. (*)
when the engine runs at high Defective adjustment of belt tension Check alternator belt tension. See
speeds. "EVERY 1000 HOURS MAINTE-
NANCE".
Defective wiring Check and repair loose terminal or
wire breakage. (*)
Lamp flickers while engine is run-
ning. Defective adjustment of belt tension Check alternator belt tension. See
"EVERY 1000 HOURS MAINTE-
NANCE".
Unusual noise is generated from al- Defective alternator Replace. (*)
ternator.
Battery charge level caution lamp Defective alternator Replace. (*)
lights up while engine is running.
Defective wiring Check, repair. (*)
Defective adjustment of belt tension Check alternator belt tension. See
"EVERY 1000 HOURS MAINTE-
NANCE".

3-240
OPERATION TROUBLES AND ACTIONS

Problem Main causes Remedy

Starting motor does not rotate even Defective wiring Check, repair. (*)
when starting switch is turned to
Defective starting motor Replace. (*)
START position.
Battery disconnect switch at OFF Turn ON.
Engine shutdown secondary switch Set it “NORMAL” position.
at “engine stop” position Install cover.
Insufficient battery charge Charge battery.
Pinion of starting motor repeats en- Insufficient battery charge Charge battery.
gaging and disengaging (rattles).
Defective starting motor Replace. (*)
Starting motor turns engine sluggish- Insufficient battery charge Charge battery.
ly.
Defective starting motor Replace. (*)
Starting motor disengages before Defective wiring Check, repair. (*)
engine starts. Defective ring gear and pinion
Insufficient battery charge Charge battery.
Preheating pilot lamp does not light Defective wiring Check, repair. (*)
up.
Defective heater relay, heater control- Replace. (*)
ler and temperature sensor
Defective monitor Replace. (*)
Engine does not start. Damaged data in the controller Check, repair. (*)
(“L04” lights up on monitor.) Other system troubles Check, repair. (*)

PHENOMENA AND ACTIONS FOR CHASSIS

• Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column.
• Ask your Komatsu distributor for repairs for problems or causes which are not listed below.
Problem Main causes Remedy
HST
Parking brake is applied. Release the parking brake.
Directional lever is not shifted in posi- Set the lever completely in position.
tion completely.
Engine runs but machine does not There is no electric current in the di- Check the fuse and wiring harness
move. rectional lever.
Add oil to specified level by referring
Lack of oil in the hydraulic tank to EVERY 100 HOURS MAINTE-
NANCE.
Add oil to specified level by referring
Machine moves slowly and lacks Lack of oil in the hydraulic tank to EVERY 100 HOURS MAINTE-
power even with engine running at NANCE.
full throttle.
Hydraulic oil temperature is low. Perform warm-up operation.
Add oil to the specified level or drain
Insufficient or excessive oil in the hy- oil to the specified level by referring
Oil is overheated. draulic tank to EVERY 100 HOURS MAINTE-
NANCE.
Oil cooler core is clogged Clean the oil cooler core.
Add oil to the specified level by refer-
Noise is generated. Lack of oil in the transfer case
ring to WHEN REQUIRED.

3-241
TROUBLES AND ACTIONS OPERATION

Problem Main causes Remedy

Axle
Add oil to the specified level by refer-
Lack of oil
ring to WHEN REQUIRED.
Noise is generated.
Improper oil is used (for machines Change the oil to the appropriate oil.
with limited slip differential)
Brake
Disc has worn to wear limit. Replace the disc. (*)
Add oil to specified level by referring
Brake does not work even when ped-
Lack of oil in the hydraulic tank to EVERY 100 HOURS MAINTE-
al is depressed.
NANCE.
Air is in brake system. Bleed air (*)
Brake drags or remains applied. Vent hole of brake valve is clogged. Clean it.
Disc has worn. Replace the disc. (*)
Large amount of water is mixed into Change the axle oil.
Brake squeals. axle oil
Axle oil is deteriorated due to over- Change the axle oil.
use of the brake.
Steering
Add oil to specified level by referring
Steering wheel is heavy to operate. Lack of oil in the hydraulic tank to EVERY 100 HOURS MAINTE-
NANCE.
Lubricate the bearing.
Play in steering cylinder pin
Change the pins and bushings. (*)
Steering wheel is jolting.
Add oil to specified level by referring
Lack of oil in the hydraulic tank to EVERY 100 HOURS MAINTE-
NANCE.
Parking brake
Braking effect is poor. Disc has worn. Replace the disc. (*)
Add oil to specified level by referring
Lack of oil in the hydraulic tank to EVERY 100 HOURS MAINTE-
Brake drags or remains applied. NANCE.
Replace the filter by referring to EV-
Hydraulic tank filter is clogged.
ERY 2000 HOURS MAINTENANCE.
Hydraulic system
Add oil to specified level by referring
Power lacks when raising the bucket. Lack of oil in the hydraulic tank to EVERY 100 HOURS MAINTE-
NANCE.
Replace the filter by referring to EV-
It takes time to raise the bucket. Hydraulic tank filter is clogged.
ERY 2000 HOURS MAINTENANCE.
Replace the oil with oil of good quali-
Poor quality of oil
ty.
Add oil to specified level by referring
Excessive bubbles are in oil. Lack of oil in the hydraulic tank to EVERY 100 HOURS MAINTE-
NANCE.
Bleed air by referring to EVERY 2000
Air is mixed into the oil system.
HOURS MAINTENANCE.

3-242
OPERATION TROUBLES AND ACTIONS

Problem Main causes Remedy

Add oil by referring to EVERY 100
Pump sucks air due to the lack of oil HOURS MAINTENANCE. And then,
Oil pressure is low.
in the hydraulic tank bleed air by referring to EVERY 2000
HOURS MAINTENANCE.
Add oil to specified level by referring
Movement of cylinder is irregular. Lack of oil in the hydraulic tank to EVERY 100 HOURS MAINTE-
NANCE.
Lock of exterior parts
Clean it with air blow or water.
Sand is inside the sliding portion of
The grille lock is too stiff to open. (Do not use oil or grease. They may
the lock.
attract the sand.)

PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS

• For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor.
• In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Problem Main causes Remedy
Engine oil pressure caution lamp Lowered oil level in engine oil pan Set oil to specified level. See
lights up. (sucking in air) CHECKS BEFORE STARTING.
Improper oil is used. (Viscosity is im- Replace oil. See USE OF FUEL,
proper.) METHOD FOR USING FUEL, COOL-
ANT AND LUBRICANTS ACCORD-
ING TO AMBIENT TEMPERATURE.
Clogged oil filter cartridge Replace cartridge. See EVERY 500
HOURS MAINTENANCE.
Oil leakage due to improper connec- Check, repair. (*)
tion or breakage of oil pipe or pipe
joint
Defective engine oil pressure sensor Replace sensor. (*)
Defective monitor Replace monitor. (*)
Steam spurts out from top of radiator Lowered coolant level, leakage of Check, add coolant, or repair. See
(pressure valve). coolant WHEN REQUIRED.
Defective fan pump or motor Check, repair. (*)
Indicator of engine coolant tempera- Accumulation of dirt or scale in cool- Check, add coolant, or repair. See
ture gauge is in red range ing system WHEN REQUIRED.
Engine coolant temperature caution Clean or repair them. See WHEN
Clogged radiator fins or damaged fin
lamp lights up. REQUIRED.
Defective thermostat Replace thermostat. (*)
Defective sealing of thermostat Replace thermostat seal. (*)
Loose radiator filler cap Tighten cap or replace packing.
(In high altitude operation)
Replace coolant temperature gauge.
Defective coolant temperature gauge
(*)
Defective coolant level sensor Replace sensor.
Defective monitor Replace. (*)

3-243
TROUBLES AND ACTIONS OPERATION

Problem Main causes Remedy

Indicator of engine coolant tempera- Defective thermostat Replace thermostat. (*)
ture gauge does not rise up to the
Replace coolant temperature gauge.
green range Defective coolant temperature gauge
(*)
Defective monitor Replace. (*)
Starting motor turns but engine does Add fuel. See CHECKS BEFORE
Lack of fuel
not start. STARTING.
Air in fuel system Repair portion where air is sucked in.
Fill filter with fuel. See EVERY 500
Fuel filter is not filled with fuel.
HOURS MAINTENANCE.
Defective fuel injection pump or injec- Replace pump or injector. (*)
tor
Starting motor turns engine sluggish- See PHENOMENA AND ACTIONS
ly. FOR ELECTRICAL SYSTEM.
See PHENOMENA AND ACTIONS
Starting motor does not turn.
FOR ELECTRICAL SYSTEM.
Preheating pilot lamp does not light See PHENOMENA AND ACTIONS
up. FOR ELECTRICAL SYSTEM.
Incorrect valve clearance Adjust valve clearance. (*)
(Defective compression)
Exhaust gas color is white or bluish. Water entry in the aftertreatment de- Check, repair. (*)
vices
Breakage of the aftertreatment devi- Replace the aftertreatment devices.
ces (*)
Excessive oil in oil pan Set oil to specified level. See
CHECKS BEFORE STARTING.
Improper fuel Replace with specified fuel.
Exhaust gas turns black from time to Breakage of the aftertreatment devi- Replace the aftertreatment devices.
time. ces (*)
Clogged air cleaner element Clean or replace. See WHEN RE-
QUIRED.
Defective injector Replace injector. (*)
Defective compression See the above section on defective
compression. (*)
Defective turbocharger Check, replace turbocharger. (*)
Combustion makes breathing sound Defective nozzle Replace nozzle. (*)
from time to time.
Abnormal noise is generated. Low grade fuel being used Replace with specified fuel.
(Combustion or mechanical) Overheating Refer to "Indicator of engine coolant
temperature gauge is in red range"
as above.
Breakage of inside of the aftertreat- Replace the aftertreatment devices.
ment devices (*)
Excessive valve clearance Adjust clearance. (*)
DEF level caution lamp lights up. Lowering of DEF level Add DEF.

3-244
OPERATION TROUBLES AND ACTIONS

IF MACHINE MONITOR SHOWS WARNING DISPLAY

When the action level display (1) or caution lamp (2) is shown
on the display of the machine monitor, press the switch (3) to
display “Current Abnormality” and check the details and reme-
dy.
For the contents of the action level display and caution lamp,
see “BASIC OPERATION OF MACHINE MONITOR WHEN
TROUBLE OCCURS WHILE OPERATING MACHINE (3-15)”.
• If “CA2249” or “CA559” is displayed on “Current Abnormal-
ity” screen although the machine has not run out of fuel,
replace both of the fuel main filter and fuel prefilter immedi-
ately.
For the method of replacement, see “METHOD FOR RE-
PLACING FUEL MAIN FILTER CARTRIDGE (4-57)”,
“METHOD FOR REPLACING FUEL PREFILTER CAR-
TRIDGE (4-55)”.
If “CA2249” or “CA559” is not cleared even after the re-
placement, the machine still can perform normal operation,
but ask your Komatsu distributor for inspection immediate-
ly.
• When failure code “CA4166 (SCR Temperature Sensor
ECU High Temperature Error)” is displayed, raise the cool-
ing fan speed by raising the engine speed to emit the heat inside the engine room.
Telephone number for the point of contact when an error occurs
When an error screen is displayed on the monitor, press the
switch (3) to display “Current Abnormality” screen and tele-
phone number for the point of contact is displayed in the mes-
sage column at the bottom of the screen.
REMARK
If no point of contact telephone number is registered, no tele-
phone number is displayed.
Ask your Komatsu distributor for the telephone number regis-
tration if necessary.

3-245
 MAINTENANCE

Please read and make sure that you understand the SAFETY section before
reading this section.

4-1
PRECAUTIONS FOR MAINTENANCE MAINTENANCE

PRECAUTIONS FOR MAINTENANCE

Do not perform any inspection and maintenance operation that are not found in this manual.

CHECK SERVICE METER READING

Check the service meter reading every day to see if the maintenance time has come for any necessary mainte-
nance item to be performed.

KOMATSU GENUINE REPLACEMENT PARTS

Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts.

KOMATSU GENUINE LUBRICANTS

For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of
the specified viscosity according to the ambient temperature.

ALWAYS USE CLEAN WASHER FLUID

Use automobile window washer fluid, and be careful not to let any dirt get into it.

FRESH AND CLEAN LUBRICANTS

Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away
from oil and grease.

CHECK DRAINED OIL AND USED FILTER

At the replacement of the filters when oil is changed, check the old oil and filters for metal particles and foreign
materials. If large quantity of metal particles or foreign materials are found, always report to the person in
charge, and perform suitable action.

PRECAUTIONS FOR REFILLING OIL OR FUEL

If your machine is equipped with a strainer, do not remove it while filling oil or fuel.

PRECAUTIONS FOR ADDING DEF

Do not remove the strainer while adding DEF.

WELDING INSTRUCTIONS
• When conducting weld repair, turn the starting switch to OFF position and, after confirming that the system
operating lamp is turned off, set the battery disconnect switch key to OFF position and pull it out.
• Do not apply a voltage higher than 200 V continuously.
• Connect grounding cable within 1 m of the area to be welded. If grounding cable is connected near instru-
ments, connectors, etc., the instruments may malfunction.
• Prevent seals, bearings or bushings from entering the space between the weld zone and grounding point.
Seals and the like can cause damage to the nearby parts by catching fire from sparks.
• Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
Sparks generated there can damage the plated portion.

DO NOT DROP THINGS INSIDE MACHINE

• When opening the inspection windows or the oil filler port of the tank to perform inspection, be careful not to
drop nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine,
and will lead to failure. If anything drops, be sure to take it out.
• Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.

PRECAUTIONS FOR KDPF

When performing inspection and maintenance during or just after regeneration, take care of the high tempera-
ture parts.
Even after the engine stops the parts around KDPF may be at high temperature.

4-2
MAINTENANCE PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS FOR SCR ASSEMBLY

Be careful for the high temperature parts when performing inspection and maintenance. Even after the engine
stops the parts around SCR device may be at high temperature.

DUSTY JOBSITES
When working at dusty jobsites, observe the following.
• Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not
to let the fins become clogged.
• Replace the fuel filter more frequently.
• Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
• When checking and replacing the oil or filters, move the machine to a place where there is no dust and take
care to prevent dust from entering the system.

AVOID MIXING OIL

Never mix different brand or grade of oil. If a different brand or grade of oil has to be added, drain the old oil and
replace all the oil with the new brand or grade of oil.

LOCK INSPECTION COVERS

Lock inspection cover securely into position with the lock bar, etc. If inspection or maintenance is performed with
inspection cover not locked in position, there is a danger that it may be suddenly shut by the wind and cause
personal injury.
When closing the inspection cover, check that it is not locked with the lock bar, etc. If it is locked and a strong
force is brought to bear on it, there is danger that it may become deformed.

BLEED AIR FROM HYDRAULIC CIRCUIT

When hydraulic equipment is repaired or replaced, or the hydraulic piping is disconnected, the air must be bled
from the circuit. For bleeding air, see “METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HY-
DRAULIC TANK STRAINER (4-63)”.

PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES

• When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace them with new parts.
When doing this, be careful not to forget to assemble O-rings and gaskets.
• When installing the hoses, do not twist them or bend them sharply.
If they are installed so, their service life will be extremely shortened and they may be damaged.

CHECKS AFTER INSPECTION AND MAINTENANCE

If you forget to perform the inspection and maintenance, unexpected problems may occur, and this may lead to
personal injury. Always observe the following.
Checks after operation (with engine stopped)
• Have any inspection and maintenance points been forgotten?
• Have all inspection and maintenance items been performed correctly?
• Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside the machine and get caught in the lever linkage mechanism.
• Are there any leakage of coolant or oil? Have all nuts and bolts been tightened?
Checks while the engine is running
• For details of the checks when the engine is running, see SAFETY,“TWO WORKERS FOR MAINTENANCE
WHEN ENGINE IS RUNNING (2-35)” and pay attention to safety.
• Do not run the engine for long hours with the engine hood open. The engine hood may be damaged by
heat of exhaust gas.
• Increase the engine speed to check for the leakage of fuel or oil.

4-3
PRECAUTIONS FOR MAINTENANCE MAINTENANCE

• Check if the inspected and serviced area is normally operated.

FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE

It is necessary to select fuel or lubricant according to the ambient temperature.
For detail, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)”.

CLOSE ENGINE SIDE COVER SECURELY

When closing the engine side cover after inspection and maintenance, lock it securely with the catcher.
If the engine side cover is not locked with the catcher, the engine side cover may open.

4-4
MAINTENANCE OUTLINE OF MAINTENANCE

OUTLINE OF MAINTENANCE
• Komatsu recommends using Komatsu genuine parts for replacement parts, grease or oil.
• When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all
the old oil and fill completely with the new oil. Always replace the filter at the same time. (There is no prob-
lem if the small amount of oil remaining in the piping mixes with the new oil.)
• Unless otherwise specified, when the machine is shipped from the plant, it is filled with the oil and coolant
listed in the table below.
Item Type
Engine oil pan Engine oil EO15W40-LA (Komatsu genuine)
Transfer case Power train oil TO10 (Komatsu genuine)
Hydraulic tank Engine oil EO10W30-DH (Komatsu genuine)
Axle Axle oil AXO80 (Komatsu genuine)
Non-Amine Engine Coolant (AF-NAC) (Komatsu genuine) (Density of 30%
Radiator
or above)

HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

OIL
• Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature,
high pressure), and deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in
Operation and Maintenance Manual.
Even if the oil is not dirty, always change the oil at the specified interval.
• Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of failures with the 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 failures.
• If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such
cases, consult your Komatsu distributor.
• When changing the oil, always replace the related filters at the same time.
• We recommend that you have an oil analysis periodically to check the condition of the machine. For those
who wish to use this service, consult your Komatsu distributor.
• When using commercially available oil, it may be necessary to reduce the oil change interval. We recom-
mend that you use the Komatsu oil clinic to check the characteristics of the oil in detail.
NOTICE
Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu
genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the en-
gine such as deteriorated oil may reduce lubricating function, and it may cause failure, shortening of
the machine life, lowering of performance and increase of fuel consumption.

FUEL
• To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel
tank with fuel after completing the day's work.
• The fuel pump is a precision equipment, 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 for the temperature that is described in Operation and Maintenance Manual.

4-5
OUTLINE OF MAINTENANCE MAINTENANCE

• If the fuel is used at the temperatures lower than the specified temperature (particularly at tempera-
tures below -15 °C), the fuel will solidify.
• If the fuel is used at temperatures higher than the specified temperature, the viscosity will drop, and it
may result in troubles such as a drop of output.
• Before starting the engine, or after 10 minutes of adding fuel, drain the sediment and water from the fuel
tank.
• If the engine runs out of fuel, or if the filters are replaced, it is necessary to bleed the air from the circuit.
• If there is any foreign material in the fuel tank, wash the tank and fuel system.
NOTICE
The fuel used must be ultra low-sulfur diesel fuel. (≤10 ppm)
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted
on this machine uses an electronically controlled high-pressure fuel injection device and emission gas
control system (KDPF). Since the high-pressure fuel injection device requires high precision parts and
lubrication, if low viscosity fuel with low lubricating ability is used, its durability may drop considerably.
And using fuel with high sulfur content can deteriorate the engine parts and KDPF catalyzer, inducing
failures, decrease of the life and degradation in performance.

COOLANT AND WATER FOR DILUTION

• The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of coolant is essential.
Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant
(AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for
2 years or 4000 hours.
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may
cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
• When using antifreeze, always observe the precautions given in Operation and Maintenance Manual.
• Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
• The coolant density needs to be changed according to the ambient temperature.
For the coolant density, see “METHOD FOR CLEANING INSIDE OF COOLING SYSTEM (4-21)”.
Even in areas where it is not considered necessary to prevent freezing, always use Non-Amine Engine
Coolant (AF-NAC) with a density of over 30 % in order to prevent corrosion of the cooling system.
Non-Amine Engine Coolant (AF-NAC) is diluted with distilled water that does not contain any ions or water-
hardening substances. Never dilute with water.
• 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 due to air
entering the coolant.

DEF
• If DEF gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes
off and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated
or begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear
rubber gloves when you perform work handling DEF to avoid skin contact.
• When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face away
from the filler port.
• Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause
a fire. Some fluids or agents added can create and emit a toxic gas.
• DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas.

4-6
MAINTENANCE OUTLINE OF MAINTENANCE

• If DEF is spilled, immediately wash and clean the area with water. If spilled DEF is left unattended and the
area is not washed and cleaned, it can cause corrosion to the contaminated area and emit toxic gas.
• When disposing of DEF, treat it as an industrial waste. The container for DEF is an industrial waste as well.
It should be treated in the same way.
• Never use an iron or aluminum container when disposing DEF, because toxic gas may develop and a
chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel
when handling the fluid waste of DEF.
NOTICE
If you add any additional additive agents or water to DEF, the devices in the Urea SCR system may be
defective, and conformance to the exhaust gas regulations will be lost.

GREASE
• Grease is used to prevent seizure and noises at the joints.
• This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom-
mended grease and follow the replacement intervals and recommended ambient temperatures given in this
Operation and Maintenance Manual.
• Grease fittings not included in the periodic maintenance section are the grease fittings 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.

PERFORM KOWA (Komatsu Oil Wear Analysis)

KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA,
the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and
other problems.
Thanks to long term experience and ample data accumulated, we can grasp condition of your machine accu-
rately and provide proper recommendation.
We strongly recommend you to use this service. The oil analysis is performed at actual cost, so the cost is low,
and results of the analysis and recommendations are reported promptly.
KOWA analysis items
Measurement of metallic powder concentration
An ICP (Inductively Coupled Plasma) analyzer is used for
measuring the concentration of iron, copper, and other metal
powder in the oil.

Measurement of quantity of iron particles

A PQI (Particle Quantifier Index) measuring instrument is used
for measuring the quantity of iron particles of 5 μm or more, en-
abling early detection of failures.

4-7
OUTLINE OF MAINTENANCE MAINTENANCE

Others
Measurements are made of items such as the ratio of water, coolant, and fuel in the oil, and dynamic viscosity, if
necessary, to enable a highly precise diagnosis of the machine and the components' condition.
Oil sampling interval
500 hours
Precautions when sampling
• Make sure that the oil is well mixed before sampling.
• Perform sampling at regular fixed intervals.
• Do not perform sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, contact your Komatsu distributor.

STORE OIL AND FUEL

• Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
• When keeping drum cans for a long period, lay the drums so that the filler ports of the drums are located in
the lower part of the side to prevent moisture from being sucked in. If drums have to be stored outside, cov-
er 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).

STORE DEF
• Completely seal up its container for storage. Only open containers in a well-ventilated area.
• When storing DEF, avoid direct sunlight. Always use the original container. Make sure that transfer equip-
ment and tank must meet DEF compatible material specification. If DEF is stored in an iron or aluminum
container, toxic gas may develop and a chemical reaction may corrode the container.
• The relationship between the upper limit of storage temperature and the storage period of DEF is shown in
the table.
Temperature of storage area Storage period
Max.10 °C Up to 36 months
Max.25 °C Up to 18 months
Max.30 °C Up to 12 months
Max.35 °C Up to 6 months

*: Do not store DEF in the temperature of 35 °C or above.

For the storage in cold weather, see the section about DEF in “COLD WEATHER OPERATION (3-229)”.

FILTER
• Filters are extremely important safety parts. They prevent impurities in the oil, fuel, and air circuits from en-
tering important equipment and causing problems. Replace all filters periodically. For details, see 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 and use again the filters (cartridge type). Always replace them with new filters.
• When replacing oil filters, check if any metal particles are attached to the old filters.
If any metal particles are found, consult your Komatsu distributor.
• Do not open packages of spare filters until just before they are to be used.
• Komatsu recommends using Komatsu genuine filters.

4-8
MAINTENANCE OUTLINE OF MAINTENANCE

HANDLE ELECTRICAL COMPONENTS

k WARNING
• When the battery disconnect switch key is turned to OFF position for the maintenance work, always
pull out the key and keep it with you. If the key is left in the switch, someone may turn ON the power
by mistake. It is dangerous that causes an electric shock.
For the operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-119)”.
• It is extremely dangerous if the electrical component becomes wet or the covering of the wiring is
damaged. This will cause an 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 components.

• When removing the connectors of electrical components after washing the machine or in the rain, wipe off
the water drop stuck around connectors before removing the connectors and keep the water drop away
from inside of the connectors.
• Checking and maintenance items are checking fan belt tension, checking damage of the fan belt and
checking battery fluid level.
• Komatsu recommends installing electric components specified by Komatsu.
• External electro-magnetic interference may cause malfunction of the control system controller. Accordingly,
consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma-
chine.
• When working at the seashore, keep the electrical component clean to prevent corrosion.
• When installing electrical component, connect it to the special power supply connector.
Do not connect the optional power supply to the fuse or starting switch or battery relay, etc.

4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE

STANDARD TIGHTENING TORQUE FOR BOLTS AND

NUTS
Tightening torque list
k 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 be
careful when tightening parts.

Unless otherwise specified, tighten the metric nuts and bolts to

the torque shown in the table below.
If it is necessary to replace any nut or bolt, Komatsu recom-
mends using Komatsu genuine part of the same size as the
part that is removed.

Thread di- Tightening torque

Width
ameter of
across flats Target value Allowable range
bolt “a”
“b” (mm)
(mm)  Nm  kgm  Nm  kgm
6 10 13.3 1.35 11.8 to 14.7 1.2 to 1.5
8 13 31 3.2 27 to 34 2.8 to 3.5
10 17 67 6.8 59 to 74 6.0 to 7.5
12 19 111 11.3 98 to 123 10.0 to 12.5
14 22 172 17.5 153 to 190 15.5 to 19.5
16 24 260 26.5 235 to 285 23.5 to 29.5
18 27 360 37 320 to 400 33 to 41
20 30 510 52.3 455 to 565 46.5 to 58
22 32 688 70.3 610 to 765 62.5 to 78
24 36 883 90 785 to 980 80 to 100
27 41 1295 133 1150 to 1440 118 to 147
30 46 1715 175 1520 to 1910 155 to 195
33 50 2205 225 1960 to 2450 200 to 250
36 55 2745 280 2450 to 3040 250 to 310
39 60 3260 333 2890 to 3630 295 to 370

Tighten the hoses by the following torque shown in the table.

4-10
MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS

Taper seal
Tightening torque
Nominal Thread size “a” Width across flats
Target value Allowable range
No. of hose (mm) “b” (mm)
 Nm  kgm  Nm  kgm
02 14 19 44 4.5 34 to 63 3.5 to 6.5
03 18 22 78 8.0 59 to 98 6.0 to 10.0
04 22 27 103 10.5 84 to 132 8.5 to 13.5
05 24 32 157 16.0 128 to 186 13.0 to 19.0
06 30 36 216 22.0 177 to 245 18.0 to 25.0
10 33 41 216 22.0 177 to 245 18.0 to 25.0

Face seal
Tightening torque
Nominal size -
Nominal Width across flats
thereads per inch Target value Allowable range
No. of hose “b” (mm)
“a”
 Nm  kgm  Nm  kgm
02 9/ 19 44 4.5 34 to 54 3.5 to 5.5
16 -18UN

03 11/ -16UN 22 74 7.5 54 to 93 5.5 to 9.5

16

04 13/ -16UN 27 103 10.5 84 to 132 8.5 to 13.5

16

05 1 -14UNS 32 157 16.0 128 to 186 13.0 to 19.0

06 1 3/16 -12UN 36 216 22.0 177 to 245 18.0 to 25.0

4-11
MAINTENANCE SCHEDULE MAINTENANCE

MAINTENANCE SCHEDULE
• When using the engine oil for cold district, the maintenance intervals of the engine oil and filter cartridge are
changed to for every 250 hours.
• If the currently used diesel fuel which does not include the bio-fuel is changed to the one mixed with the
bio-fuel, the replacement interval of the fuel filter is changed as well. See “MAINTENANCE INTERVAL
WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED”.
• Ask your Komatsu distributor for changing the maintenance interval of the machine monitor.
MAINTENANCE SCHEDULE TABLE
INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) ................................................ 4-15
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) .......................................... 4-15
WHEN REQUIRED ........................................................................................................................................ 4-15
METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER .......................................... 4-15
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM ................................................................. 4-21
METHOD FOR CHECKING OIL LEVEL IN TRANSFER CASE AND ADDING OIL................................. 4-25
METHOD FOR CLEANING ENGINE DAMPER BREATHER .................................................................. 4-27
METHOD FOR CHECKING OIL LEVEL IN AXLE CASE AND ADDING OIL........................................... 4-28
METHOD FOR CLEANING AXLE BREATHER....................................................................................... 4-29
METHOD FOR CLEANING AIR CONDITIONER CONDENSER............................................................. 4-30
METHOD FOR CLEANING RADIATOR FIN AND COOLER FIN ............................................................ 4-31
METHOD FOR CLEANING FINS BY ROTATING COOLING FAN IN REVERSE .................................... 4-31
METHOD FOR REVERSING MANUAL OPERATION FAN ..................................................................... 4-31
METHOD FOR REVERSING AUTOMATIC OPERATION FAN ............................................................... 4-31
METHOD FOR CLEANING FIN WITH COMPRESSED AIR ................................................................... 4-31
METHOD FOR INVERTING AND REPLACING BOLT ON CUTTING EDGE .......................................... 4-33
METHOD FOR REPLACING BUCKET TEETH....................................................................................... 4-34
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID ................................. 4-37
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER................................................. 4-37
METHOD FOR REPLACING SLOW-BLOW FUSE ................................................................................. 4-39
METHOD FOR CHECKING FUNCTION OF ECSS ACCUMULATOR..................................................... 4-40
METHOD FOR CHECKING FUNCTION OF BRAKE ACCUMULATOR .................................................. 4-40
SELECT AND CHECK TIRES................................................................................................................. 4-41
METHOD FOR CLEANING AND REPLACING FUEL TANK BREATHER ELEMENT ............................. 4-42
CHECKING AUTO-GREASING AND OPERATION METHOD FOR FILLING GREASE.......................... 4-44
CHECKS BEFORE STARTING...................................................................................................................... 4-44
EVERY 50 HOURS MAINTENANCE ............................................................................................................. 4-46
METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK ............................................. 4-46
EVERY 100 HOURS MAINTENANCE ........................................................................................................... 4-46
METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL ....................................... 4-46
METHOD FOR CLEANING AIR CONDITIONER FRESH AIR FILTER.................................................... 4-47
EVERY 250 HOURS MAINTENANCE ........................................................................................................... 4-47
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL ............................................................. 4-47
METHOD FOR TESTING PARKING BRAKE .......................................................................................... 4-49
METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.. 4-49
METHOD FOR CHECKING LOOSENESS OF WHEEL HUB BOLTS, RETIGHTENING BOLTS ............ 4-51
METHOD FOR CLEANING AIR CONDITIONER RECIRC AIR FILTER .................................................. 4-52
METHOD FOR CHECKING FUNCTION OF BRAKE ACCUMULATOR .................................................. 4-52
EVERY 500 HOURS MAINTENANCE ........................................................................................................... 4-53
METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGE .....
............................................................................................................................................................ 4-53
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................... 4-55
EVERY 1000 HOURS MAINTENANCE ......................................................................................................... 4-57
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE ............................................................ 4-57
METHOD FOR CLEANING TRANSFER CASE BREATHER .................................................................. 4-59
METHOD FOR CHANGING OIL IN TRANSFER CASE AND CLEANING TRANSFER CASE STRAINER .....
............................................................................................................................................................ 4-59
METHOD FOR REPLACING HST OIL FILTER CARTRIDGE ................................................................. 4-61

4-12
MAINTENANCE MAINTENANCE SCHEDULE

METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS.............. 4-63
METHOD FOR CHECKING AND REPLACING ALTERNATOR BELT..................................................... 4-63
EVERY 2000 HOURS MAINTENANCE ......................................................................................................... 4-63
METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER... 4-63
METHOD FOR REPLACING HYDRAULIC OIL FILTER CARTRIDGE.................................................... 4-66
METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ............................................. 4-68
METHOD FOR CHANGING OIL IN AXLE CASE .................................................................................... 4-69
METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC AIR FILTERS ................................ 4-70
METHOD FOR CLEANING BRAKE CIRCUIT STRAINER...................................................................... 4-71
METHOD FOR CHECKING BRAKE DISC WEAR AMOUNT .................................................................. 4-72
METHOD FOR CHECKING FUNCTION OF PPC ACCUMULATOR ....................................................... 4-73
METHOD FOR CHECKING ALTERNATOR ............................................................................................ 4-73
METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE ...................................... 4-74
METHOD FOR CHECKING VIBRATION DAMPER ................................................................................ 4-74
METHOD FOR REPLACING KCCV FILTER ELEMENT ......................................................................... 4-74
METHOD FOR REPLACING DEF FILTER.............................................................................................. 4-77
METHOD FOR REPLACING DEF TANK BREATHER ELEMENT........................................................... 4-79
EVERY 4000 HOURS MAINTENANCE ......................................................................................................... 4-80
REPLACE DEFINED LIFE PARTS.......................................................................................................... 4-80
METHOD FOR LUBRICATING DRIVE SHAFT ....................................................................................... 4-81
METHOD FOR CHECKING WATER PUMP............................................................................................ 4-82
METHOD FOR CHECKING STARTING MOTOR.................................................................................... 4-82
METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR............................ 4-82
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH-PRESSURE PIPING CLAMP, HARD-
ENING OF RUBBER ........................................................................................................................... 4-82
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.
............................................................................................................................................................ 4-83
METHOD FOR CHECKING WEAR OF DAMPER GEAR........................................................................ 4-83
EVERY 4500 HOURS MAINTENANCE ......................................................................................................... 4-83
METHOD FOR CLEANING KDPF .......................................................................................................... 4-83
METHOD FOR CLEANING DEF TANK................................................................................................... 4-83
EVERY 8000 HOURS MAINTENANCE ......................................................................................................... 4-83
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP............................................................ 4-83
METHOD FOR REPLACING STARTING MOTOR .................................................................................. 4-83
EVERY 9000 HOURS MAINTENANCE ......................................................................................................... 4-84
METHOD FOR REPLACING DEF HOSE ............................................................................................... 4-84
END OF SERVICE LIFE ......................................................................................................................... 4-84

MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS

USED
If the diesel fuel which does not include the bio-fuel is changed to the diesel fuel mixed with bio-fuel, set the
maintenance interval as follows.
Replace the fuel prefilter cartridge
When the machine is operated first 250 hours after the diesel fuel has been changed to the diesel fuel mixed
with bio-fuel, and when the machine is operated further 250 hours.
After that, replace it within 500 hours as a periodic replacement by the service meter reading.
Replace the fuel main filter cartridge
When the machine is operated first 250 hours after the diesel fuel has been changed to the diesel fuel mixed
with bio-fuel, and when the machine is operated further 250 hours.
After that, replace it within 1000 hours as a periodic replacement by the service meter reading.

4-13
MAINTENANCE SCHEDULE MAINTENANCE

Maintenance interval after the diesel fuel has been changed to the diesel fuel mixed with bio-fuel
Operating hours of the machine Service meter
Every 500 hours Every 1000 hours
250 hours 500 hours Within 500 After 500 op- Within 500 After 500 op-
When
after chang- after chang- operating erating hours operating erating hours
changed
ing ing hours after after chang- hours after after chang-
changing ing changing ing
Fuel prefilter
Replace. Replace. Replace. - Replace. - Replace.
cartridge
Fuel main fil-
Replace. Replace. Replace. - - - Replace.
ter cartridge

4-14
MAINTENANCE MAINTENANCE PROCEDURE

MAINTENANCE PROCEDURE
INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS)
For the first 100 hours of operation on a new machine, press
the switch shown in the figure every 10 hours to actuate the
manual greasing.

INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250

HOURS)
Perform the following maintenance work only after the first 250 hours of operation on new machines.
• Replace HST oil filter cartridge
• Replace hydraulic oil filter cartridge
For details of the method of replacement or maintenance. See EVERY 1000 HOURS MAINTENANCE and EV-
ERY 2000 HOURS MAINTENANCE.

WHEN REQUIRED
METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER
k WARNING
• When using compressed air, there is a danger that dirt may scatter and cause personal injury.
Always wear protective eyeglasses, dust mask, or other protective equipment.
• When removing the outer element from the air cleaner body, it is dangerous to pull it out by force.
When working in high places or where the foothold is poor, be careful not to fall because of the re-
action when pulling out the outer element.

4-15
MAINTENANCE PROCEDURE MAINTENANCE

NOTICE
• Do not clean the element before the air cleaner clogging caution lamp on the machine monitor
lights up, or the yellow piston of the dust indicator laps over the peripheral red zone (7.5 kPa,
{0.076 kg/cm2}).
If the element is cleaned frequently before the air cleaner clogging caution lamp on the machine
monitor lights up or the yellow piston of the dust indicator laps over the peripheral red zone
(7.5 kPa, {0.076 kg/cm2}), the air cleaner will not be able to display its performance fully, and the
cleaning efficiency will also go down.
In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner
element.
• If any dirt enters the engine, it can damage the engine. Be sure to stop the engine before checking,
cleaning, or servicing the air cleaner. Do not check, clean, or service the air cleaner in strong winds,
or in a dusty place.
In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner
element.
• Replace the outer element if it is cleaned 6 times repeatedly or used throughout a year. Replace the
inner element as well at the same time.

METHOD FOR CHECKING AIR CLEANER

NOTICE
The electric air cleaner clogging sensor and dust indicator are used to indicate the clogging on the air
cleaner. The electric air cleaner clogging sensor indicates the cleaning timing of the air cleaner element
and the dust indicator indicates the level of clogging.
Check the dust indicator before operating the machine so that cleaning of the air cleaner element is not
required during operation.
1. Open the engine side cover (1) on the right side of the ma-
chine.

2. Clean the element when the yellow piston shown in the

dust indicator (2) display of the air cleaner enters the red
(7.5 kPa, {0.076 kg/cm2}) position.
After the cleaning, press the dust indicator button to reset
it.
If the yellow piston enters the red (7.5 kPa, {0.076 kg/cm2})
position soon after the cleaning, the element must be re-
placed.
For the replacement of the element, see “METHOD FOR
REPLACING AIR CLEANER ELEMENT (4-19)”.

4-16
MAINTENANCE MAINTENANCE PROCEDURE

Electric air cleaner clogging sensor

Clean the air cleaner element when the yellow piston of dust in-
dicator (2) display enters the red (7.5 kPa, {0.076 kg/cm2}) po-
sition or the air cleaner clogging caution lamp (3) of the ma-
chine monitor lights up.

METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT

1. Open the engine side cover (1) on the right side of the ma-
chine.

2. Remove the clips (2) (4 places) and remove the cover (3).

3. Pull out the outer element (4).

NOTICE
Never remove the inner element (5). Dusts may enter,
causing the engine failure.

4. Clean the inside of the air cleaner body, cover (3) and va-
cuator valve (6).

4-17
MAINTENANCE PROCEDURE MAINTENANCE

NOTICE
Do not clean and reuse the inner element. When replacing the outer element, replace the inner element
with a new one at the same time.
When cleaning the element, do not tap it or hit it against something.
Do not use the element with damaged pleats or a damaged gasket or seal.
Wrap an unused element and keep it in a dry place.
5. Blow dry compressed air (0.2 MPa {2.1 kg/cm2}) from the
inside of the outer element along the pleats.
6. Blow along the pleats from the outside, then blow again
from the inside.

7. Peel off a seal after cleaning the element each time.

8. After cleaning, illuminate the inside of the element with an

electric bulb to check.
If the element has a small hole or thin part, replace it.

k CAUTION
When installing the cover (3), check O-ring (7) for scratches or damages and replace O-ring with a new
one if any.

9. Set the cleaned outer element (4).

10. Install the cover (3) and fix it with clip (2).

4-18
MAINTENANCE MAINTENANCE PROCEDURE

11. Push the button of dust indicator.

The yellow piston returns.
12. Close the engine side cover (1) on the right side of the ma-
chine.

Even though the outer element has not been cleaned up to 6 times, if the yellow piston of dust indicator laps
over the red zone (7.5 kPa, {0.076 kg/cm2}) soon after the cleaning, or if the air cleaner clogging caution lamp
lights up, replace both the inner and outer elements.

METHOD FOR REPLACING AIR CLEANER ELEMENT

1. Open the engine side cover (1) on the right side of the ma-
chine.

2. Remove the clips (2) (4 places) and remove the cover (3).

3. Pull out the outer element (4).

Do not remove the inner element (5) at this time.
4. Clean the interior of the air cleaner body, cover (3) and va-
cuator valve (6) with a clean cloth, a whisk or others.
5. Remove the inner element (5), then install the new inner
element immediately.

4-19
MAINTENANCE PROCEDURE MAINTENANCE

NOTICE
Be sure to install the air cleaner element facing in the cor-
rect direction.
Install it so that the bottoms (A) and (B) of the air cleaner
element (face where no hole is drilled) come to the cover
(3) end. If it is installed in wrong direction, it may cause
breakage of the air cleaner element or serious damage to
the engine.

6. Install the cover (3) according to the following procedure.

1) Set the new outer element (4).
2) Replace the O-ring (7) with a new one.
3) Install the cover (3) and fix it with clip (2).

7. Push the button of dust indicator.

The yellow piston returns.

8. Replace the seal (8) on the cover (3) with a new one.
9. Close the engine side cover (1) on the right side of the ma-
chine.

4-20
MAINTENANCE MAINTENANCE PROCEDURE

METHOD FOR CLEANING INSIDE OF COOLING SYSTEM

k WARNING
• Immediately after the engine is stopped, the coolant is still hot and the pressure is accumulated in
the radiator. If the cap is removed under this condition and the coolant is drained, it may cause a
burn. Always wait for the temperature to go down, and turn the cap slowly to release the pressure.
• Start the engine and perform the cleaning. When standing up or leaving the operator's seat, set the
lock lever to LOCK position.
• For starting the engine, see OPERATION, MACHINE OPERATIONS AND CONTROLS, “CHECKS AND
ADJUSTMENT BEFORE STARTING ENGINE (3-151)”, and “METHOD FOR STARTING ENGINE
(3-176)”.
• Keep away from the rear of the machine while the engine is running. Because the engine is operat-
ed during cleaning, the machine may suddenly move, and you may be hit if you are standing behind
it.

Place the machine on a level ground when cleaning or changing the coolant.
For cleaning the inside of the cooling system and changing the coolant, see the following table.
Interval for cleaning inside of cooling system and
Coolant
changing coolant
Non-Amine Engine Coolant Every 2 years or every 4000 hours whichever
(AF-NAC) comes sooner

The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of coolant is essential.
Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC).
Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be
used continuously for 2 years or 4000 hours.
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC).
If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts
of the cooling system.
To maintain the anti-corrosion properties of Non-Amine Engine Coolant (AF-NAC), always keep the density of
Non-Amine Engine Coolant between 30 % and 64 %.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water. When using the coolant, investigate
the lowest temperature in the past and decide the density for the coolant from the coolant density table below.
When deciding the density for the coolant, set it for a temperature 10 °C below the actual lowest temperature in
the working area.
The coolant density varies according to the ambient temperature, but it must be over 30 % at least.

Coolant density table

Min. atmospheric tem- -10 or
 °C -15 -20 -25 -30 -35 -40 -45 -50
perature more
Density ( %) 30 36 41 46 50 54 58 61 64

4-21
MAINTENANCE PROCEDURE MAINTENANCE

k WARNING
• Coolant is toxic. When opening the drain valve, be careful not to get coolant on you. If it gets in
your eyes, flush your eyes with large amount of fresh water and see a doctor immediately.
• When handling the cooling water containing coolant that has been drained during changing the
coolant or repairing the radiator, contact your Komatsu distributor or request a qualified company
to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the
ground surface.

Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable. (For dilution
water, see “COOLANT AND WATER FOR DILUTION (4-6)”.)
Check the density with a coolant tester.
Items to be prepared
• A container whose capacity is enough to receive the specified capacity of coolant
• A hose to add coolant
1. Place the machine on a level ground, then stop the engine.
2. Remove the radiator top cover (1).

3. Check that the coolant temperature is low enough to touch

the radiator cap surface by bare hand, turn the radiator
cap (2) slowly until it hits the stopper, and release the pres-
sure.
4. Then, while pushing the radiator cap (2), turn it until it
touches the stopper, and remove it.

5. Open the engine side cover (3) on the left side of the ma-
chine.
6. Prepare a container to catch the coolant.

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MAINTENANCE MAINTENANCE PROCEDURE

7. Open the drain valve (4) at the bottom of the radiator and
drain the coolant.
8. Tighten the drain valve (4) and add tap water.
Add water until it fills the radiator.
9. Start the engine.

10. Depress the accelerator pedal (5) lightly and run the en-
gine at a medium speed for approximately 5 minutes with
no load.

11. Check that the engine rotation has become smoother, then
press the work equipment lock switch (6) to release the
work equipment lock (pilot lamp goes out).
12. Operate the multifunction mono-lever (7) to “TILT” position
(e) and to “HOLD” position (b) repeatedly to warm up the
hydraulic oil.
Oil reaches the relief pressure through the above opera-
tions and hydraulic oil gets warmer in a shorter time.

13. Turn the steering wheel slowly approximately 10 times to the right and left to warm up the hydraulic oil in
the steering valve.

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MAINTENANCE PROCEDURE MAINTENANCE

k WARNING
If you turn the steering wheel and stop turning it at
certain position while the oil temperature is low, a time
lag may result until the machine stops after the turning
operation.
In such case, set the frame lock bar to LOCK position
(L) for safety and perform the warm-up operation in a
large place.
At that time, be sure not to relieve the oil pressure in
the circuit for more than 5 seconds.

Repeating the operations from step 11 to 13 moves the

pointer of the engine coolant temperature caution lamp (8)
upward. The pointer of the engine coolant temperature
caution lamp (8) once drops at around the center of scale
(A), after that, continue the above operations for approxi-
mately 10 seconds.
14. Stop the engine.

15. Open the drain valve (4) to drain the coolant.

16. Close the drain valve (4).
17. Add the Non-Amine Engine Coolant through the coolant
filler port up to the mouth of the port.
For the concentration of Non-Amine Engine Coolant, see
“Coolant density table”.
NOTICE
Add less than 12 ℓ/min of the Non-Amine Engine Cool-
ant. If large amount of coolant is added at a time, more
air is mixed into the coolant, and the cooling perform-
ance may be lowered. It will cause overheat.
18. Run the engine at low idle for 5 minutes to remove the air from the coolant, then run at high idle for a further
5 minutes.
Keep the radiator cap (2) removed during the above operations.

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MAINTENANCE MAINTENANCE PROCEDURE

19. Drain the coolant in reservoir tank (9).

20. Clean the inside of reservoir tank (9).
21. Add the Non-Amine Engine Coolant to the middle between
FULL and LOW.
22. Stop the engine.
23. Approximately 3 minutes later, add the Non-Amine Engine
Coolant up to the mouth of the coolant filler port.
24. Tighten the radiator cap (2).
25. Install the cover (1) on the top of the radiator.
26. Close the engine side cover (3) on the left side of the ma-
chine.

METHOD FOR CHECKING OIL LEVEL IN TRANSFER CASE AND ADDING OIL
k WARNING
• Apply the parking brake and fix the front and rear frames by using the frame lock bar.
• Immediately after the engine is stopped, parts and oil are still very hot. Wait for the temperature to
go down, and then start the work.

If ooze of oil is recognized on the transfer case, perform the checks.

1. Start the engine.
2. Perform the warm-up operation of the transfer.
After finishing the warm-up operation, keep running the engine at low idle for 5 minutes or longer.
REMARK
The completion of the warm-up operation of the transfer means that the oil temperature of the transfer is
warmed to approximately 40 °C to 60 °C. As a reference, after 30 to 40 minutes traveling, the machine rea-
ches almost this state usually.
When the ambient temperature is low (0 °C or less), perform the warm-up operation of the transfer by trav-
eling approximately 1 hour as a reference.

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MAINTENANCE PROCEDURE MAINTENANCE

3. While running the engine at low idle, remove the cap of oil
filler port (F).
4. Pull out the dipstick (G) and wipe the oil off with a cloth.
5. Fully insert the dipstick (G) into the dipstick pipe, then re-
move it.
REMARK
Whenever inserting the dipstick, be sure to insert it into the
dipstick pipe.
The oil level is correct if it is between the marks (A) and (B)
on dipstick (G) marked with “HOT IDLE” side.
6. If the oil level is below the mark (B), add oil through the oil
filler port (F).

7. If the oil level is above the mark (A), drain the excessive oil
through drain plug (P), and then check the oil level again.
8. If the oil is at the correct level, insert the dipstick (G) into
the dipstick pipe and tighten the cap.

NOTICE
• The oil level changes according to the oil temperature. Check the oil level after completing the
warming-up operation of the transfer.
• If the oil temperature of the transfer is low, the oil level at low idling becomes lower than the mark
(B) on “HOT IDLE” side.
(If the oil volume is correct, the oil level is between the marks (A) and (B) on “HOT IDLE” side after
the transfer oil becomes warm.)

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MAINTENANCE MAINTENANCE PROCEDURE

Method for checking oil level when the engine is stopped

• As a reference, check the marks (C) and (D) on dipstick
(G) marked with “COLD STOP” side.
• Stop the engine, and wait for 2 hours or longer before
checking.
• For the final oil level check, use “HOT IDLE” side of dip-
stick (G) according to the preceding steps 1 to 8, after
completing the warm-up operation of the transfer.

METHOD FOR CLEANING ENGINE DAMPER BREATHER

k WARNING
Immediately after the engine is stopped, parts and oil are still very hot. Wait for the temperature to go
down, and then start the work.

1. Remove the bolts (1) (3 pieces) and remove the cover (2).

2. Remove the bolts (3) (4 pieces) and remove the cover (4).

3. After removing dirt and dusts around the breather (5), re-
move the breather (5) and immerse it in detergent liquid to
clean.
While the breather is removed, use care to prevent entry of
dusts through the mounting location of the breather.

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MAINTENANCE PROCEDURE MAINTENANCE

METHOD FOR CHECKING OIL LEVEL IN AXLE CASE AND ADDING OIL
k WARNING
• When checking the oil level, apply the parking brake and fix the front and rear frames using the
frame lock bar.
• Immediately after the engine is stopped, parts and oil are still very hot. Wait for the temperature to
go down, and then start the work.

If ooze of oil is recognized on the axle case, perform the checks.

Place the machine on a level ground before starting the check.
(If the machine is inclined in the right or left, the oil level cannot be checked correctly.)
A: Front, B: Rear
1. Stop the engine and remove plug (1).
2. Wipe off oil of dipstick (G) installed to plug (1) with a cloth.

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MAINTENANCE MAINTENANCE PROCEDURE

3. Set dipstick (G) as shown in the figure.

(2): Axle
(3): Spot facing surface
4. Check the oil level.
The level is appropriate if it is between 2 grooves (H) and
(L) of the dipstick
REMARK
Be careful that the amount of the lubricating oil for the axle
with Limited Slip Differential may be different. Always use
the specified lubricating oil.
5. If the oil does not reach the lower groove (L), supply the
axle oil from oil filler port (F).
6. If the oil level exceeds the upper groove (H), drain the ex-
cessive oil through drain plug (P), and then check the oil
level again.
7. If the oil level is appropriate, install plug (1).
Tightening torque: 93 to 123 Nm {9.5 to 12.5 kgm}

METHOD FOR CLEANING AXLE BREATHER

k WARNING
When cleaning, apply the parking brake and fix the front and rear frames by using the frame lock bar.

A: Front, B: Rear
1. Remove mud and dust around the breather by using a
brush, etc.
2. Remove the breather, immerse it in detergent liquid, and
clean it.
• Clean the breathers in 2 locations, the front and rear
sides.
• While the breather is removed, use care to prevent
entry of dusts through the mounting location of the
breather.

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MAINTENANCE PROCEDURE MAINTENANCE

METHOD FOR CLEANING AIR CONDITIONER CONDENSER

k WARNING
• Do not use a steam cleaner for the cleaning since it is dangerous as the condenser is heated.
• If the pressurized water hits a person directly or dirt scatters by using pressurized water, there is a
danger of personal injury.
Wear the protective equipment such as the protective eyeglasses and dust mask.

If dirt or dust is stuck to the condenser, clean them by using water.

If water pressure is excessive, the fin may be deformed. So cleaning by using pressurized water must be done
from a sufficiently distant position.
1. Open the engine side covers (1) and (2) on the right and
left sides of the machine.

2. Remove the mounting bolts (4) of condenser (3) (2 places

each on the right and left).

3. Hold the top of the condenser (3) and tilt it backward.

A gap is made between the condenser (3) and radiator (5).
4. Clean the condenser with water through this gap.
5. Restore the condenser (3) to the original position and in-
stall it with the mounting bolt (4).
6. Close the engine side covers (1) and (2) on the right and
left sides of the machine.

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MAINTENANCE MAINTENANCE PROCEDURE

METHOD FOR CLEANING RADIATOR FIN AND COOLER FIN

k WARNING
• When the engine is running, do not open the engine side cover. When cleaning the fin, stop the en-
gine rotation completely.
• If compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by the
compressed air, high-pressure water, or steam, there is a danger of personal injury. Always wear
protective equipment such as protective eyeglasses and dust mask.

Perform this procedure if there is any mud or dirt stuck to the radiator.

METHOD FOR CLEANING FINS BY ROTATING COOLING FAN IN REVERSE

NOTICE
When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth, etc.
will not be wound in the fan.
Since dust may be blown up, check that there is no people around while the fan is rotating in reverse.
On the job site where the dirt sticks easily to radiator or cooler, set the automatic cooling fan to rotate the fan in
reverse. This will blow off any dirt stuck to radiator or cooler, and can extend the cleaning interval.

METHOD FOR REVERSING MANUAL OPERATION FAN

NOTICE
• Never rotate the fan in reverse by hand when performing the operation.
• Before operating the manual reverse rotation of the fan, set the engine speed to low idle.
For the manual reverse rotation of the fan, see “RADIATOR FAN MANUAL REVERSE MODE (3-59)”.
• After reverse rotation of the fan is started, set the engine speed to high idle.
• Set the high idle operation time as follows, depending on the clogging level.
Ordinary clogging: 1 to 2 minutes
Excessive clogging: 2 to 3 minutes
When the cleaning is completed, set the engine speed to low idle and restore the rotation of the fan to normal.

METHOD FOR REVERSING AUTOMATIC OPERATION FAN

For the automatic reverse rotation of the fan, see “RADIATOR FAN AUTOMATIC REVERSE MODE (3-61)”.
REMARK
• When the fan rotation direction is switched, the fan reverse rotation pilot lamp flashes.
After a heavy load operation, the fan rotation direction may not change to protect the machine.
Set the engine speed to low idle and wait until the oil and coolant temperature goes down before operating
the switch.
• In a cold circumstance, perform the cleaning by Fan Reverse Mode within less than 5 minutes.
If the fan reverse rotation is performed for a long time, DEF hose may freeze.

METHOD FOR CLEANING FIN WITH COMPRESSED AIR

k WARNING
When opening fan guard, stop the engine, and display warning tag on multifunction mono-lever.

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MAINTENANCE PROCEDURE MAINTENANCE

METHOD FOR CLEANING FINS WITH REAR GRILLE OPENED

1. Open the rear grille (1).

2. Push the lever (2) lightly to the right and open the fan
guard (3).

3. Blow off mud, dirt, leaves, etc. in radiator fins (4) with com-
pressed air.
NOTICE
Steam or water may be used instead of the com-
pressed air.
However, when using the powerful steam cleaning
equipment (high-pressure machine wash) for the heat
exchange equipment (radiator and cooler), keep a suf-
ficient distance to the target.
If steam cleaning (high-pressure machine wash) is per-
formed at close distance, there is a danger that the in-
ternal fins of the heat exchange equipment may be de-
formed, and this will cause early clogging and break-
age of the equipment.
4. Check the rubber hoses. If any hose is cracked or hardened by age, replace it with a new one. Also check
and tighten all the loose hose clamps.
5. After cleaning, close the fan guard (3) and rear grille (1).

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MAINTENANCE MAINTENANCE PROCEDURE

METHOD FOR CLEANING FIN WITH ENGINE SIDE COVER OPEN

1. Open the engine side covers (1) and (2) on the right and
left sides of the machine.

2. Insert the air nozzle through the clearance between the ra-
diator, oil cooler, aftercooler (3), and air conditioner con-
denser (4) to clean.
Steam or water may be used instead of the compressed
air.
3. Check the rubber hoses. If any hose is cracked or hard-
ened by age, replace with a new one. Also check and
tighten all the loose hose clamps.
4. Insert the air nozzle and blow off the dirt or dusts accumu-
lated onto the fuel tank toward the front of the machine.
Steam or water may be used instead of the compressed air.

METHOD FOR INVERTING AND REPLACING BOLT ON CUTTING EDGE

k WARNING
It is dangerous if the work equipment moves by mistake when the cutting edge or end bit is being re-
placed.
Set the work equipment in a stable condition, stop the engine, then lock the work equipment (the pilot
lamp in the switch lights up).

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 a block (A)
under the bucket to prevent the bucket from lowering.
Raise the bucket to make its bottom surface level.
2. Remove bolts and nuts (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 turning the edge, install it to the opposite side (left
edge to right side, right edge to left side).

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MAINTENANCE PROCEDURE MAINTENANCE

If both sides of the cutting edge are worn out, replace with new ones.
If the wear extends to the mounting surface, repair the mounting surface before installing the cutting edge.
5. Tighten bolts and nuts (1) uniformly so that there is no gap between the bucket and cutting edge (2).
Tightening torque of mounting bolt: 883 to 1196 Nm {90 to 122 kgm}
6. After operating for several hours, retighten the mounting bolts.

METHOD FOR REPLACING BUCKET TEETH

(if equipped)

k WARNING
• It is dangerous if the work equipment moves by mistake when the tooth is being replaced.
Set the work equipment in a stable condition on a ground, stop the engine, then press the work
equipment lock switch to lock the work equipment securely (the work equipment lock pilot lamp
lights up).
• If the pin is driven out with strong force, it is dangerous that the pin flies out. Check that there is no
person around the machine.
• Always wear the protective equipment such as protective eyeglasses and gloves since broken
pieces fly during the replacement work.

METHOD FOR REPLACING MONOBLOC TYPE TEETH

Replace the bucket teeth before the wear reaches to the edge of the bucket.
1. Raise the bucket to a suitable height, then put a block (A)
under the bucket to prevent the bucket from lowering.
Set the bottom of bucket to be level, and put a block under
the bucket at the center.
2. Lower the bucket on the block and stabilize it.
3. Stop the engine.
4. Remove the bolts and nuts (1) and (2), and remove the
bucket teeth (3).
5. Clean the mounting surface of bucket teeth (3).
6. Install a new teeth to the bucket.
Eliminate the clearance between the teeth and top face of the bucket by inserting shims.
Continue the adjustment with shims until the insertion of 0.5 mm thick of shim becomes impossible.
If the wear extends to the mounting surface, repair the mounting surface before installing.
7. In order to eliminate the clearance between the bucket teeth and the top end of the bucket, tighten bolts
and nuts (1) and (2) lightly, then tap the teeth ends by using a hammer.
Tightening torque of mounting bolt
(1) : 1200 to 1330 Nm {122 to 136 kgm}
(2) : 814 to 912 Nm {83 to 93 kgm}
8. After operating for several hours, retighten the mounting bolts.

METHOD FOR REPLACING TIP TYPE TEETH

Replace the tooth before the wear reaches to the adapter.

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MAINTENANCE MAINTENANCE PROCEDURE

1. Raise the bucket to a suitable height, then put a block (A)

under the bucket to prevent the bucket from lowering.
Set the bottom of bucket to be level, and put a block under
the bucket at the center.
2. Lower the bucket on the block and stabilize it.
3. Stop the engine.

4. Fit the round bar which is slightly thinner than the pin (2),
and hit the round bar with the hammer to drive out the pin
(2).
5. Remove the tooth (1).
REMARK
If it cannot be removed by this method, for safety, ask your
Komatsu distributor to have the replacement performed.

6. Clean the bucket adapter (3) thoroughly.

7. Install a new bucket tooth to the bucket adapter (3).
8. Insert the pin (2) into the bucket tooth, and hit it with the
hammer.

9. If the mounting bolts (4) and (5) of the bucket adapter (3)
are loose, retighten them.
Tightening torque of mounting bolt
(4) : 1200 to 1330 Nm {122 to 136 kgm}
(5) : 814 to 912 Nm {83 to 93 kgm}
10. After operating several hours, check that the pin does not
come out.

METHOD FOR REPLACING KMAX TEETH

(if equipped)
Replace the tooth before the wear reaches to the adapter.
Items to be prepared
Socket wrench with 11 mm of width across flats and torque wrench
REMARK
The wear will become uniform by rotating the mounting position of the tooth. This will extend the service life of
the tooth and reduce the frequency of replacement.

4-35
MAINTENANCE PROCEDURE MAINTENANCE

1. Raise the bucket to a suitable height, then put a block (A)

under the bucket to prevent the bucket from lowering.
Set the bottom of bucket to be level, and put a block under
the bucket at the center.
2. Lower the bucket on the block and stabilized it.
3. Stop the engine.

4. Fit the socket wrench to the shaft of pin (1), and turn it
counterclockwise by 90 ° to unlock the pin.

5. Push out pin (1) to the direction of arrow by hand or ham-

mer, and remove tooth (2).
6. Check the torque to unlock the pin by using torque wrench
according to the following procedure.
1) Rotate the shaft of pin (1) with torque wrench, and set
it to the lock state (90 °).
2) Rotate the shaft from the lock state (90 °) to free state
(0 °).

3) Check that the maximum torque is 11 Nm {1.12 kgm} and above.

If the torque value is low, replace the pin with a new
one.
T1: Torque (Nm)
T2: Turning angle (degree)
REMARK
The torque value increases gradually and reaches to
the maximum at approximately 45 °, and it decreases
gradually after 45 °.

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MAINTENANCE MAINTENANCE PROCEDURE

7. Clean the mounting surface of tooth (2).

8. Fit new tooth (2) to the adapter.
9. Insert pin (1), rotate the shaft of the pin clockwise by 90 °
with socket wrench to lock the pin, and install the tooth.

10. Check that the shaft of pin (1) is locked securely.

Be careful of the direction of brim of the shaft.
(A) Free state: The brim of shaft is sideways.
(B) Lock state: The brim of shaft is upward.
11. After operating several hours, check that the pin does not
come out.

METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID

1. Open the cover inside the left step.
2. Check the water level in window washer tank (1), and if it
is insufficient, add the window washer fluid for automo-
biles.
Be careful not to let dirt or dust get in when adding it.
3. After checking the fluid level, close the cover.

METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER

METHOD FOR CHECKING LEVEL OF REFRIGERANT (GAS)
k WARNING
If the refrigerant used in the air conditioner gets into your eyes or is splashed on your hands, it may
cause loss of sight or frostbite. Never touch the refrigerant. Do not loosen any part of the refrigerant
circuit.
Do not bring any open flame close to any point where the refrigerant gas is leaking.

1. Start the engine and set the engine speed to approximate-

ly 1500 rpm.
2. Press the fan switch (1) and set the air flow to “MAX”.
3. Press the temperature adjustment switch (2) and set the
temperature to 18 °C.
4. Fully open the doors and windows.
5. Press the air conditioner switch (3) to turn on the air condi-
tioner switch.

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MAINTENANCE PROCEDURE MAINTENANCE

6. Open the engine side cover (4) on the left side of the ma-
chine.

7. Check the condition of the refrigerant gas (Hydrofluorocar-

bons HFC-134a) that circulates the refrigerant circuit,
through the sight glass (6) (inspection window) of the re-
ceiver drier (5).

(A) Just after the air conditioner switch is turned on, a

small number of bubbles are seen. After a while, the
sight glass becomes milky white, and then becomes
pale: Appropriate
(B) After the air conditioner switch is turned on, bubbles
are seen continuously: Insufficient

Condition viewed through the

State of refrigerant flow
sight glass

Bubbles are seen: Gaseous and liquid refrigerants are mixed.

No bubble: All refrigerant becomes liquid and transparent.

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MAINTENANCE MAINTENANCE PROCEDURE

Condition viewed through the

State of refrigerant flow
sight glass

Milky white: Oil and refrigerant are separated and their mixture is milky white.

MAINTENANCE AND SCHEDULE OF AIR CONDITIONER

Maintenance schedule
Check point Check items Check before op- 6 months inspec- Replacement in-
eration tion terval
Filter Clogging, dirt Implement - 2 years
Condenser Clogging, dirt Implement - -
Belt Looseness, damage Implement - 2 years
Refrigerant gas Charge amount - Implement -
Looseness, damage, leak-
Piping - Implement -
age
Receiver drier - - - 2 years

METHOD FOR REPLACING SLOW-BLOW FUSE

NOTICE
• When replacing the slow-blow fuse, be sure to turn the starting switch to OFF position and, after
confirming that the system operating lamp is not lit, set the battery disconnect switch key to OFF
position.
• Replace the slow blow fuse with the one of the same capacity.
Should the slow-blow fuse is blown, investigate the cause and take necessary actions.
The slow-blow fuse is on the side of the engine on the left side of the machine.
1. Remove the cover (1).
2. Open the cover (2) of the slow-blow fuse box and check it.

3. Turn the starting switch to OFF position (A).

4. Turn the battery disconnect switch key to OFF position.
Check that the system operating lamp is not lit.
5. Remove the slow-blow fuse box from the machine body.

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MAINTENANCE PROCEDURE MAINTENANCE

6. Open the covers (3), (4) and (5) of the slow-blow fuse box.
You can remove the box easily by removing the covers (4)
and (5) with a flat-head screwdriver using the projection (6)
as a fulcrum.
7. Loosen the screws (7) and (8) and remove them.
When you remove the screws (7) and (8), the slow-blow
fuse (9) comes off along with electric wirings (10) and (11).
8. Install a new slow-blow fuse to the slow-blow fuse box
along with the electric wirings (10) and (11) with screws (7)
and (8).
9. Close the covers (3), (4), and (5).
10. Install the slow-blow fuse box to the machine.

METHOD FOR CHECKING FUNCTION OF ECSS ACCUMULATOR

For handling of the accumulator, see “HANDLE ACCUMULATOR AND GAS SPRING (2-40)”.
1. Turn on the ECSS switch.
The function of the hydraulic spring of the accumulator reduces the bounce of the machine by absorbing
the vertical motion of the machine during travel.
2. Compare the vertical motion of the machine when the ECSS switch is turned to ON position and OFF posi-
tion.
If there is no change in the vertical motion, the accumulator gas pressure has probably dropped.
Ask your Komatsu distributor for inspection.
REMARK
Perform the inspection while the travel speed is 10 km/h or higher. ECSS (Electronically Controlled Suspen-
sion System) does not operate when the travel speed is 5 km/h or lower even if the ECSS switch is turned
on.

METHOD FOR CHECKING FUNCTION OF BRAKE ACCUMULATOR

When the brake pedal is depressed, the hydraulic spring effect of the accumulator actuates the brake smoothly.
If any change is felt in the smoothness of the brake operation during daily operations, the gas pressure in the
accumulator has probably dropped.
Ask your Komatsu distributor for inspection.
REMARK
Even if there is any change in the smoothness, there is no drop in the braking force or brake performance.

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MAINTENANCE MAINTENANCE PROCEDURE

SELECT AND CHECK TIRES

k WARNING
If a tire or a rim is handled improperly, the tire may burst or
may be damaged and the rim may be broken and scat-
tered, and that can cause serious injury or 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 do the work.
• Never perform welding or light a fire near the tire.

TIRE SELECTION
k WARNING
Select the tires according to the conditions of use and the weight of the 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 the weight of the attachments of the machine.
Use the tires shown in the following table.
The travel speed displayed varies with the tire size.
NOTICE
For usability of tires, consult your Komatsu distributor.
• Do not install the tire protector (mesh chain) to rear wheels.
• Do not to use tires, such as urethane tires, that weigh remarkably more than the standard tires
since the machine can be damaged due to an unexpected load.
• If a tire not specified by Komatsu is used, rim displacement between the tire and rim may occur.
Operator comfort, as well, may be degraded.
Maximum load (kg) Tire size
Front tire: 8000 Front tire: 20.5R25☆ (L3 Rock)
Radial
Rear tire: 8000 Rear tire: 20.5R25☆ (L3 Rock)
Front tire: 6775 Front tire: 20.5-25-12PR
Bias
Rear tire: 6775 Rear tire: 20.5-25-12PR

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MAINTENANCE PROCEDURE MAINTENANCE

METHOD FOR CHECKING AND INFLATING TIRE

k WARNING
• When pumping up the tires, check that no other person is standing near the tire, and install an air
chuck with a clip that can be secured to the air valve.
• To prevent the tire inflation pressure from becoming too high, measure the pressure from time to
time with an air gauge while pumping up the tire.
• When it is inflated, the rim parts may fly out, if they are not fitted properly.
Put a fence around the tire for protection. The worker must not stand in front of the rim but must
stand on the tread side during work.
• Abnormal drop of inflation pressure and abnormal fitting of the rim indicate a trouble in the tire or
rim. In this case, be sure to ask a tire repair shop for repair.
• Be sure to observe the specified inflation pressure.
• Do not adjust the tire inflation pressure immediately after traveling at high speed or operating under
heavy load.

Check the tire inflation pressure before starting work while the tires are cold.
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.

1. Measure the inflation pressure with a tire inflation pressure gauge.

2. Adjust the inflation pressure properly.
The proper inflation pressure is shown below.
Tire size Standard inflation pressure
Front wheel: 425 kPa {4.25 kg/cm2}
Radial 20.5R25☆ (L3 Rock)
Rear wheel: 400 kPa {4.0 kg/cm2}
Front wheel: 330 kPa {3.3 kg/cm2}
Bias 20.5-25-12PR
Rear wheel: 280 kPa {2.8 kg/cm2}

NOTICE
Appropriate inflation pressure varies depending on the given type of work. For details, see “HAN-
DLE TIRE (3-211)”.

METHOD FOR CLEANING AND REPLACING FUEL TANK BREATHER ELEMENT

k CAUTION
If you perform inspection or cleaning while the engine is running, dirt enters the fuel tank and damages
the engine.
Be sure to stop the engine before performing these works.

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MAINTENANCE MAINTENANCE PROCEDURE

1. Open the engine side cover (1) on the left side of the ma-
chine and open the rear grille (2).

2. Loosen the nut (4) at the top of the fuel tank breather (3)
which is located on the left upper of the fan guard, and re-
move it.
3. Turn the cover (5) counterclockwise and remove it.

4. Remove the element (6) upwards.

5. Blow the dry compressed air from the inside of the ele-
ment.

6. After cleaning, install the element to the breather body.

At that time, install the element in correct direction.
Direct the surface having the mark shown by (7) toward up
to install.
7. Install the cover (5).
8. Tighten the nut (4).
Tightening torque: 10 to 14 Nm {1.0 to 1.4 kgm}
9. Close the engine side cover (1) and rear grille (2).
NOTICE
If the element is extremely dirty or damaged, replace it
with a new one.

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MAINTENANCE PROCEDURE MAINTENANCE

CHECKING AUTO-GREASING AND OPERATION METHOD FOR FILLING

GREASE
NOTICE
• Fill in only clean grease by using a suitable tool (A).
Soiled lubricant leads to serious system trouble.
• If the grease tank is emptied below “min” mark, the air
bleeding of whole system must be performed.
To bleed air from the auto-greasing system, consult
your Komatsu distributor.
Maintenance work should be performed if needed or every 50
hours.
If any problem occurs, consult your Komatsu distributor.
Prepare the grease.
For the types of grease, see “METHOD FOR USING FUEL,
COOLANT AND LUBRICANTS ACCORDING TO AMBIENT
TEMPERATURE”.

• Check the general control function according to the following procedure.

1. Actuate the manual greasing.
2. Check the function of the control unit and system components.
• Check the system components for leakage and damage.
Perform the check periodically.
• Check the bearings visually.
Check that the bearings have been lubricated properly.
• Before reaching “min” mark, refill the grease tank with grease to “max” mark.
The grease amount between the marks “min” and “max” is approximately 1.6 ℓ.
By the factory settings, one filling is enough to use for at least 50 hours.
If the lubrication settings have been changed or some additional lubrications have been performed, check
the grease level earlier.
Depending on the machine equipment, there are following possibilities to refill the grease tank.
(1) Taper type grease nipple
(2) Filling port
The fittings must be free of dirt.
The transparent grease tank allows visual fill level control.

CHECKS BEFORE STARTING

For details of the following items, see the pages where they are explained.
Checks before starting engine.
“METHOD FOR WALK-AROUND CHECK (3-151)”
• Check the work equipment, cylinders, linkage, and hoses for damage, wear, play.
• Remove dirt and debris from the center hinge portion.
• Remove dirt and debris from around the engine, battery, and radiator.
• Check the engine and related parts for leakage of water, oil and exhaust gas.
• Check the fuel line for leakage.

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MAINTENANCE MAINTENANCE PROCEDURE

• Check the DEF line for leakage.

• Remove dirt from around the aftertreatment devices.
• Check around the aftertreatment devices for gas leakage.
• Check the KCCV piping for gas leakage and oil leakage.
• Check around the SCR for exhaust gas leakage.
• Check the HST piping, transfer case, axle, hydraulic tank, hoses, and joints for oil leakage.
• Check the brake line for oil leakage.
• Check the tires, wheels, and wheel hub bolts and nuts for damage and wear, and check the mounting bolts
and nuts for looseness.
• Check the handrails and steps for breakage and loose bolts.
• Check the gauges and monitor for problem.
• Check the rear view mirror.
• Check the air cleaner mounting bolts for looseness.
• Check the battery terminals for looseness.
• Check the seat belt and mounting hardware.
• Clean the cab windows.
• Check the tires.
• Check the rims.
• Check the rear view monitor.
“METHOD FOR CHECKING BEFORE STARTING (3-153)”
• Method for checking water separator, drain water and sediment.
• Method for checking coolant level, adding coolant.
• Method for checking oil level in engine oil pan, adding oil.
• Method for checking dust indicator.
• Method for checking electric wiring.
• Method for checking fuel level, adding fuel.
• Method for checking DEF level and adding DEF.
• Method for checking tire pressure.
• Method for checking window washer fluid spouting out.
• Method for checking wiper function.
• Method for checking machine monitor.
• Method for checking horn.
• Method for checking defroster function.
• Method for checking locks.
• Method for checking alternate exit of cab.
“METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE (3-180)”
• Method for checking starting condition and unusual noise of engine.
• Method for checking low-speed run and acceleration of engine.
• Method for testing parking brake.
• Method for checking brake.
• Method for checking clearance between brake pedal and floor.
• Method for checking abnormal points detected up to previous day.
• Method for Running-in the new machine.
• Method for operations after starting engine.

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MAINTENANCE PROCEDURE MAINTENANCE

EVERY 50 HOURS MAINTENANCE

METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK
1. Place a container to catch drained fuel under drain valve
(1) on the left side of the fuel tank.
2. Open drain valve (1) on the left side of the fuel tank, and
drain the sediment and water accumulated at the bottom
together with fuel.
3. When only the clean fuel flows out, close drain valve (1).

EVERY 100 HOURS MAINTENANCE

Maintenance for every 50 hours service should be performed at the same time.

METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL

k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in-
jury. Wait for the temperature to go down, and then start the work.
• When removing the oil filler cap, the oil may spurt out. Turn it slowly to release the internal pres-
sure, then remove it carefully.

NOTICE
If the oil is added to above H mark, stop the engine and wait for the hydraulic oil to cool down. Then
drain the excessive oil through the drain plug. It may damage the oil circuit and cause the oil to spurt
out.
Lower the bucket to the ground and stop the engine. Wait for 5 minutes before checking the oil level. Oil level
should be between H and L marks of the sight gauge (G).
1. Check with the sight gauge (G).

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MAINTENANCE MAINTENANCE PROCEDURE

2. If it is below the L level, refill the hydraulic oil according to

the following procedure.
1) Remove the bolts (1) (2 pieces) and remove the cover
(2).
2) Add the hydraulic oil through oil filler port (F).

METHOD FOR CLEANING AIR CONDITIONER FRESH AIR FILTER

k WARNING
When using compressed air, there is a danger that dirt may scatter and cause personal injury. Wear the
protective equipment such as the protective eyeglasses and dust mask.

When the air conditioner is used, clean the air conditioner fresh air filter.
Before cleaning the filter, stop the air conditioner.
1. Insert the starting switch key into key slot (1) and release
the lock.
2. Loosen the knob (2) and open the cover (3).

3. Loosen the knob (4) and take out the filter (5) to clean it.
4. Blow dry compressed air (0.2 MPa {2.1 kg/cm2} or less)
from the inside of the filter along the pleats.
Next, blow along the pleats from the outside, then blow
again from the inside.
Replace the filter with a new one when the dirt clogged to
the filter cannot be removed by air blow, or replace it every
year.
5. After cleaning, restore the filter (5) again, and close the
cover (3).
At this time, lock it with the starting switch key. Do not forget to remove the starting switch key.
REMARK
If the filter becomes clogged, the air flow will be reduced, and there will be a rumbling sound from the air
conditioner unit.

EVERY 250 HOURS MAINTENANCE

Maintenance for every 50 hours service should be performed at the same time.

METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL

Perform this procedure before operating the machine.
Inspect the battery electrolyte level according to the standard at least once a month.

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MAINTENANCE PROCEDURE MAINTENANCE

k WARNING
• Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. If you do so, it will
reduce the service life of the battery. In addition, it may cause an explosion.
• The battery generates inflammable hydrogen gas and there is a danger of explosion. Do not bring
any open flame near the battery.
• Battery electrolyte is dangerous object. If it gets in your eyes or on your skin, wash it off with a
large amount of water and consult a doctor.
• Do not use a dry wipe to clean the battery. A wet wipe will prevent fire or explosion from static elec-
tricity.

NOTICE
• Do not add the electrolyte to the battery exceeding UPPER LEVEL line. If the electrolyte level is too
high, it may leak and cause damage to the paint surface or corrode other parts.
• If there is a fear that the battery water may freeze after refilling with purified water (such as a com-
mercial battery fluid), do the replenishment before the day's work on the next day.

METHOD FOR CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY

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.
One each of the battery box is provided on both sides of
the rear part of the machine.
2. Clean around the electrolyte level line with a cloth wet with
water.
Check that the electrolyte level is between UPPER LEVEL
(U.L.) line and LOWER LEVEL (L.L.) line.
3. When the electrolyte level is below the center between
UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.), remove
cap (1) immediately.
4. Add purified water (example: commercially available battery liquid) up to UPPER LEVEL (U.L.)
5. When you add the purified water to the cell of cap (1), add
it to other cells as well.
6. Clean the vent hole of the battery cap, then close the cap
securely.
Keep the battery top surface clean and wipe off dirt on it
using a wet cloth.
REMARK
If purified water is added to above the UPPER LEVEL
(U.L.) line, use a syringe to lower the level to the UPPER
LEVEL (U.L.) line. Neutralize the removed fluid with baking
soda (sodium bicarbonate), then flush it away with a large
amount of water. If necessary, consult your Komatsu dis-
tributor or a battery manufacturer.

METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO

CHECK FROM SIDE OF BATTERY
If it is impossible to check the electrolyte level from the side of the battery, or there is no UPPER LEVEL line on
the side of the battery, check according to the following procedures.
1. Open the cover of the battery box.
One each of the battery box is provided on both sides of the rear part of the machine.

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MAINTENANCE MAINTENANCE PROCEDURE

2. Remove cap (1) at the top of the battery and check the
electrolyte level through electrolyte filler port (2).
3. If the electrolyte does not reach the sleeve (3), always add
the purified water (e.g. commercially available replenish-
ment water for a battery) so that the level reaches the bot-
tom of the sleeve (UPPER LEVEL line).
• (A) Correct level: Electrolyte level is up to bottom of
sleeve, so surface tension causes electrolyte surface
to bulge and pole plate appears to be warped.
• (B) Low level: Electrolyte level does not reach the bot-
tom of sleeve, so pole plate appears straight and not
to be warped.
4. When you add the purified water to the cell of cap (1), add
it to other cells as well.
5. After adding the purified water, tighten cap (1) securely.
REMARK
If the purified water is added to above the bottom of the
sleeve, use a syringe to remove electrolyte. Neutralize the
removed fluid with baking soda (sodium bicarbonate), then
flush it away with a large amount of water. If necessary,
consult your Komatsu distributor or a battery manufacturer.

METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS POSSIBLE TO

USE INDICATOR TO CHECK ELECTROLYTE LEVEL
If it is possible to use an indicator to check the electrolyte level, follow the instructions given.

METHOD FOR TESTING PARKING BRAKE

1. Stop the machine by using the brake pedal on a dry slope road (downhill).
2. Set the parking brake switch from OFF position (B) to ON
position (A).
3. Check that the machine is stopped and held at the current
position.
If any problem is found, ask your Komatsu distributor for
adjustment.

METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR

BELT TENSION
k WARNING
When checking and adjusting the air conditioner compressor belt tension, stop the engine, and display
the warning tag on the multifunction mono-lever.

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MAINTENANCE PROCEDURE MAINTENANCE

METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT

1. Open the engine side cover (1) on the right side of the ma-
chine.

2. Check air conditioner compressor belt.

Press the middle point between air conditioner compressor
pulley (2) and crankshaft pulley (3) with your thumb (ap-
proximately 98 N {10 kg}).
If deflection (a) is 11 to 15 mm, the belt tension is normal.
If the deflection is out of the standard range, adjust it into
the standard range.
When you use a belt tension gauge, the tension is normal
if it is in the range of 353 to 530 N {36 to 54 kg}.

METHOD FOR TESTING WHEN AIR CONDITIONER COMPRESSOR BELT IS RE-

PLACED
Press the middle point between the compressor pulley and crankshaft pulley with your thumb (approximately
98 N {10 kg}  ).
The standard deflection is 8 to 11.5 mm.
When you use a belt tension gauge, the tension is normal if it is in the range of 530 to 745 N {54 to 76 kg} .
REMARK
When the belt is replaced with a new one, the above value is employed as the initial tension since a stronger
tension is required.

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MAINTENANCE MAINTENANCE PROCEDURE

METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT

1. Open the engine side cover (1) on the right side of the ma-
chine.

2. Loosen bolts (2) and (3).

REMARK
When the bolts (2) and (3) are loosened, bracket (5) to
which compressor (4) is installed can move, using the
mounting position of bolt (3) as a fulcrum.
3. Loosen nut (6) which is installed to the bracket first, and
then tighten bolt (7). Compressor (4) moves in direction A,
and compressor belt can be stretched.
4. After adjusting the belt tension properly, tighten nut (6) until
it touches boss (8) and tighten it further in direction B.
Tightening torque: 59 to 74 Nm {6 to 7.5 kgm}
5. Tighten bolts (2) and (3), and fix bracket (5).
Tightening torque
Bolt (2): 98 to 123 Nm {10 to 12.5 kgm}
Bolt (3): 98 to 123 Nm {10 to 12.5 kgm}
NOTICE
• Check each pulley for damage, wear of the V-
groove, and the wear of the V-belt. In particular, be
sure to check that the V-belt is not touching the
bottom of the V-groove.
• Replace the belt with a new one if the belt is
stretched and has no allowance for adjustment, or
has slipping sound or squeak because of cuts or
cracks of the belt.
• When the new V-belt is installed, readjust it after
operating for 1 hour.

METHOD FOR CHECKING LOOSENESS OF WHEEL HUB BOLTS, RETIGHTEN-

ING BOLTS
Loosening of wheel hub bolt (1) accelerates the wear of the tires and causes accidents.

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MAINTENANCE PROCEDURE MAINTENANCE

1. Check the bolt for loosening and tighten it further if neces-

sary.
Always turn the bolts in the direction of tightening.
Tightening torque: 785 to 980 Nm {80 to 100 kgm}
2. If the bolt is broken, replace all of the bolts of the wheel.

METHOD FOR CLEANING AIR CONDITIONER RECIRC AIR FILTER

k WARNING
When using conditioner fresh air filter, there is a danger that dirt may scatter and cause personal injury.
Always wear protective equipment such as protective eyeglasses and dust mask.

1. Loosen knob (1) and tilt the top of filter inspection cover (2)
together with the filter.

2. Remove cover (2) and filter together in the direction of the

arrow.
3. Remove the filter from cover (2).
4. Clean it by using compressed air as you did for the fresh
air filter.
Replace the filter with a new one when the dirt clogging
the filter cannot be removed by blowing air or every year.
5. When installing the filter, fit it to cover (2) first.
Insert the filter and cover (2) together between the filter
box and the floor mat from a diagonally upper position.
6. Tighten the knob aligning it with the knob installation position.
REMARK
If the filter becomes clogged, the air flow will be reduced, and there will be a rumbling sound from the air
conditioner unit.

METHOD FOR CHECKING FUNCTION OF BRAKE ACCUMULATOR

If the engine stops during travel, the brake can be operated with the oil pressure in the accumulator temporarily.
1. Park the machine on a level ground and lower the work equipment to the ground.
2. Apply the parking brake.
3. Start the engine and run it at medium speed for 1 minute and then stop it.
4. Turn the starting switch to ON position and repeat depressing the brake pedal.
• If the brake oil pressure caution lamp does not light up when the brake pedal is depressed 6 times, the
gas pressure in the accumulator is normal.

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MAINTENANCE MAINTENANCE PROCEDURE

• If the brake oil pressure caution lamp lights up when the brake pedal is depressed 5 times or less, the
gas pressure in the accumulator may be low. Ask your Komatsu distributor for inspection.
REMARK
The inspection must be done within 5 minutes after the engine stops. If the engine is kept stopped, the gas
pressure in the accumulator lowers and the inspection cannot be made.

EVERY 500 HOURS MAINTENANCE

Maintenance for every 50, 100 and 250 hours should be performed at the same time.

METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL
FILTER CARTRIDGE
k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Wait for the temperature to go down, and then start the work.
• When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it carefully.

Refill capacity: 23 ℓ

Items to be prepared
• Container to catch drained oil
• Filter wrench
1. Open the engine side cover (1) on the right side of the ma-
chine.

2. Open engine oil filler (F).

3. Place an oil container right under drain plug (P) to catch
the drained oil.
4. Remove drain plug (P) and drain the oil.
Check the drained oil. If it contains much metallic powder
or foreign material, contact your Komatsu distributor.
5. Tighten drain plug (P).

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MAINTENANCE PROCEDURE MAINTENANCE

6. Open the engine side cover (2) on the left side of the ma-
chine.

7. Turn filter cartridge (3) counterclockwise by using the filter

wrench, and remove it.
If this operation is performed immediately after stopping
the engine, a large amount of oil will come out, so wait for
10 minutes before starting the work.
8. Clean filter head (4), fill the new filter cartridge with clean
engine oil, coat the seal and thread of the new filter car-
tridge with engine oil (or apply thin film of grease), then in-
stall it.
REMARK
Check that there is no old packing stuck to filter head (4). If
there is any old packing stuck to the holder, it will cause
leakage of oil.
9. When installing the cartridge, tighten it until the sealing surface contacts filter head (4), then tighten it 3/4
turn.
10. After replacing the filter cartridge, refill with engine oil through oil filler port (F) until the oil level is between H
and L marks on dipstick (G).
11. Run the engine at low idle for a while and then stop it.
The following procedure must be done after 15 minutes or longer elapsed after the engine is stopped.
12. Pull out the dipstick (G) and wipe the oil off with a cloth.
13. Fully insert the dipstick (G) into the dipstick pipe, then pull it out.
14. Check that the oil level is between H and L marks on the
dipstick (G).

REMARK
When the ambient temperature is low, water or emulsified matter may stick to the dipstick, oil filler cap, etc. or
the drained oil may be milky white because of water vapor in the blowby gas. However, if the coolant level is
normal, it is not a problem.
There is no problem even if the emulsified matter cannot be removed completely after changing oil.

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MAINTENANCE MAINTENANCE PROCEDURE

METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE

k WARNING
• Immediately after the engine is stopped, the parts are still very hot. Do not replace the filter immedi-
ately. Wait for all parts to cool down before starting the work.
• High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before replacing the filter.
• Do not bring any open flame close.

NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing the parts, Komatsu recommends using Komatsu genuine parts.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu-
ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Never use a substitute.
• When performing inspection and maintenance of the fuel system, be careful not to let any foreign
material get in, more than ever before. If dust sticks to the fuel system, wash it off thoroughly with
fuel.
Items to be prepared
• Container to catch the drained fuel
• Filter wrench
When replacing the fuel main filter cartridge (every 1000 hours), replace the fuel prefilter cartridge first.
1. Open the engine side cover (1) on the right side of the ma-
chine.
2. Place a container under the fuel prefilter cartridge to re-
ceive the fuel.

3. Loosen the drain valve (2) and drain the water and sedi-
ments from transparent cup (3), and also drain all the fuel
from filter cartridge (4).
4. Disconnect the connector (5).
5. Wrap the connector (5) with a plastic bag, etc. so that fuel,
oil and water do not get onto the disconnected connector.
6. Remove the clip (6) of sensor harness.
7. Turn the transparent cup (3) counterclockwise by using the
filter wrench, and remove it.
Transparent cup (3) is used again.
8. Turn the filter cartridge (4) counterclockwise by using the filter wrench, and remove it.
9. Install the currently removed transparent cup (3) to the bottom of the new fuel prefilter cartridge.
At this time, be sure to replace the O-ring (7) with a new one.

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MAINTENANCE PROCEDURE MAINTENANCE

NOTICE
When installing the transparent cup, thinly apply oil to the packing surface, contact it to the sealing
surface of filter cartridge (4), and then tighten it 1/4 to 1/2 turn.
If the transparent cup is tightened too much, O-ring may be damaged, and this will cause the leak-
age of fuel. If it is not tightened enough, fuel will leak through the gap at O-ring. Be sure to observe
the tightening angle.
10. Clean the filter head.
11. Fill the new filter cartridge with clean fuel.
NOTICE
• When filling the filter cartridge with fuel, do not re-
move the cap (A) at the center. Always fill with fuel
from the small holes (B) (8 places) on the dirty
side.
• After filling with fuel, remove the cap (A) and in-
stall the fuel filter.
• Always fill with clean fuel. Be careful not to let any
dirt or dust get into the fuel. In particular, center
portion is the clean side, so do not remove the cap
(A) when filling with fuel. Be careful not to let dirt
or dust get into the center portion on the clean
side.
12. Thinly apply oil to the packing surface of the new filter cartridge, then install the filter cartridge to the filter
head.
NOTICE
• When installing the filter cartridge, tighten it 3/4 of a turn after the packing surface contacts the
seal surface of the filter head.
If the filter cartridge is tightened too much, the packing may be damaged and this will cause the
leakage of fuel. If it is not tightened enough, fuel will leak through the gap at packing. Be sure to
observe the tightening angle.
• When tightening with a filter wrench, be extremely careful not to dent or damage the filter.
13. Check that the drain valve (2) is tightened securely.
14. Install the clip (6) of sensor harness.
15. Remove the plastic bag wrapping the connector (5), then connect the connector (5).
REMARK
• If water gets on the connector (5), the sensor may
malfunction and the water separator caution lamp may
flash. When removing the connector (5), be extremely
careful not to let water get on the connector.
• If water gets on the connector (5), dry it completely
before connecting it.
16. After completing the replacement of the filter cartridge (4),
bleed air from the circuit.
Bleed the air as follows.
1) Fill up the fuel tank with fuel (to the level where the
float is at the highest position).
2) Loosen the knob of feed pump (8), pull it out once, then pump it in and out until the movement be-
comes heavy.
REMARK
It is not necessary to remove the plugs at the fuel prefilter head and at the fuel main filter head.

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MAINTENANCE MAINTENANCE PROCEDURE

17. After bleeding air, push in the knob of feed pump (8) and tighten it.
18. After replacing the filter cartridge, start the engine and run it at low idle for 10 minutes.
19. Check the filter seal surface and the mounting face of the transparent cup for fuel leakage.
If there is any leakage of fuel, check the tightening condition of the filter cartridge.
If there is still fuel leakage, perform the steps 1 to 8 to remove the filter cartridge, and if any damage or
pinched foreign material on the packing surface is found, replace it with a new cartridge and repeat the
steps 9 to 19.
REMARK
When bleeding air, air may remain inside of the water separator. However, the engine can be started after
pumping the feed pump (8) in and out until it becomes heavy. Leave it as it is for a while after stopping the
engine, and air is bled spontaneously.

EVERY 1000 HOURS MAINTENANCE

Maintenance for every 50, 100, 250 and 500 hours service should be performed at the same time.

METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE

k WARNING
• Immediately after the engine is stopped, the parts are still very hot. Do not replace the filter immedi-
ately. Wait for all of parts to cool down before starting the work.
• High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before replacing the filter.
• Do not bring any open flame close.

NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing parts, Komatsu recommends using Komatsu genuine parts.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu-
ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Never use a substitute.
• When performing inspection and maintenance of the fuel system, be careful not to let any foreign
material get in, more than ever before. If dust sticks to the fuel system, wash it off thoroughly with
fuel.
• After removing the filter cartridge, fuel drops fall down from the filter head.
In order to prevent outflow of the fuel, be sure not to leave the machine while the filter cartridge is
being removed.
Items to be prepared
• Container to catch the drained fuel
• Filter wrench
After replacing the fuel prefilter cartridge, replace the fuel main filter cartridge.

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MAINTENANCE PROCEDURE MAINTENANCE

1. Open the engine side cover (1) on the right side of the ma-
chine.
2. Place a container under the filter cartridge to catch the
fuel.

3. Turn filter cartridge (2) counterclockwise by using the filter

wrench, and remove it.

4. Clean the filter head.

Replace inner seal (3) with a new one.

5. Thinly apply oil to the packing surface of the new filter cartridge, then install the filter cartridge to the filter
head.
NOTICE
• Do not fill the new filter cartridge with fuel.
• Remove cap (A) at center and install the filter car-
tridge.
6. When installing the cartridge, tighten it until the packing
surface contacts the sealing surface of the filter head, then
tighten it 3/4 turn.
REMARK
If the filter cartridge is fastened too much, the packing will
be damaged and this leads to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing
clearance. Be sure to observe the tightening angle.
When tightening with a filter wrench, be extremely careful
not to dent or damage the filter.
7. After completing the replacement of filter cartridge (2), bleed air from the circuit.
Bleed the air as follows:

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1) Fill up the fuel tank with fuel (to the level where the
float is at the highest position).
2) Loosen the knob of feed pump (4), pull it out, then
pump it in and out until the movement becomes
heavy.
REMARK
It is not necessary to remove the plugs at the fuel prefilter
head and at the fuel main filter head.
8. Push in and tighten the knob of feed pump (4).
9. After replacing the filter cartridge, start the engine and run
it at low idle for 10 minutes.
10. Check the filter seal surface for fuel leakage.
If there is any leakage of fuel, check the tightening condition of the filter cartridge.
If there is still leakage of fuel, follow steps 2 and 3 to remove the filter cartridge, then check the packing
surface for damage or foreign material. If any problem is found, replace the cartridge with a new one, then
repeat steps 4 to 10 to install the filter cartridge.
REMARK
When bleeding air, air may remain inside of the water separator. However, the engine can be started after
pumping feed pump (4) in and out until it becomes heavy. Leave it as it is for a while after stopping the engine,
and air is bled spontaneously.

METHOD FOR CLEANING TRANSFER CASE BREATHER

1. Loosen the bolts (1) (4 pieces) and remove the cover (2).

2. After removing dirt and dusts around the breather (3), re-
move the breather (3) and immerse it in detergent liquid to
clean.
While the breather is removed, use care to prevent entry of
dusts through the mounting location of the breather.

METHOD FOR CHANGING OIL IN TRANSFER CASE AND CLEANING TRANSFER

CASE STRAINER
k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in-
jury. Wait for the temperature to go down, and then start the work.
• When removing the oil filler cap, the oil may spurt out. Turn it slowly to release the internal pres-
sure, then remove it carefully.

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Refill capacity: 5.8 ℓ
Items to be prepared
• Container to catch the drained oil
1. Place a container under the drain plug (P) to catch the oil.
2. Remove the drain plug (P) and drain the oil.
Loosen the drain plug (P) gradually so that the oil will not
spurt out, and then remove it.
3. After draining the oil, install the drain plug (P).

4. Remove the bolts (1) (5 pieces) and remove the cover (2)
and tube (3).
5. Take out the strainer (4).
6. Remove the dirt, etc. from the strainer (4), then wash it in
the clean diesel fuel or flushing oil.
If the strainer (4) is damaged, replace it with a new one.
7. Install the strainer (4) to the case.
Replace the O-ring (5) of cover (2) with a new one and in-
stall the tube (3).

8. Add the refill capacity of oil through the oil filler port (F).

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9. After adding oil, check that the oil level is correct by refer-
ring to “METHOD FOR CHECKING OIL LEVEL IN
TRANSFER CASE AND ADDING OIL (4-25)”.
NOTICE
• Before starting the engine, check that the oil level
is between the marks (C) and (D) on the side of
dipstick which has a stamped mark of “COLD
STOP”.
• When checking the oil level, start the engine first.
After finishing the warm-up operation of the trans-
fer, perform the final check by using the side of
dipstick which has a stamped mark of “HOT IDLE”
according to the “METHOD FOR CHECKING OIL
LEVEL IN TRANSFER CASE AND ADDING OIL
(4-25)”.
10. Check the transfer case for oil leakage.

METHOD FOR REPLACING HST OIL FILTER CARTRIDGE

k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in-
jury. Wait for the temperature to go down, and then start the work.
• When removing the oil filler cap, the oil may spurt out. Turn it slowly to release the internal pres-
sure, then remove it carefully.

Items to be prepared
• Container to catch the drained oil
• Filter wrench
1. Loosen the bolts (1) (4 pieces) and remove the cover (2).

2. Turn the filter cartridge (3) counterclockwise by using the

filter wrench, and remove it.
3. Clean the filter head and install the new filter cartridge.
When installing the cartridge, tighten it until the packing
surface contacts the seal surface of the filter holder, then
tighten it 1/2 of a turn by using the filter wrench.
Tightening torque : 29 to 39 Nm {3.0 to 4.0 kgm}
4. Run the engine at low idle for 5 minutes to bleed air from
the HST circuit.

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5. Check the hydraulic oil level.

If the oil level is between H and L of sight gauge (G), it is
proper.
6. If it is below the L level, refill the hydraulic oil according to
the following procedure.

1) Remove the bolts (4) (2 pieces) and remove the cover

(5).

2) Add the hydraulic oil through oil filler port (F).

3) Install the cover (5) with bolts (4) (2 pieces).
7. Run the engine at low idle, and extend and retract each of
the steering, bucket, and boom cylinders 4 to 5 times, tak-
ing care not to move them to the stroke end (stop them ap-
proximately 100 mm short of the stroke end).
NOTICE
If the engine is run at high speed immediately after the
startup or a cylinder is pushed up to its stroke end, air
taken inside the cylinder may cause damage to the
piston packing, etc.
8. Extend and retract each of the steering, bucket, and boom cylinders to the stroke end 3 to 4 times.
9. Stop the engine, loosen the cap of the oil filler port, and bleed air from the hydraulic tank.
10. Check the hydraulic oil level approximately 5 minutes later.
If the oil level is between H and L of sight gauge (G), it is proper.
11. After bleeding air, install the cover (2) with bolts (1) (4 pieces).
12. Check the HST oil filter for oil leakage.
When the HST oil filter clogging caution lamp lights up, replace the HST filter element even if it has not yet been
used for 1000 hours or 1 year.

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METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE

CLAMPS
Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner - turbocharger -
aftercooler - engine.

METHOD FOR CHECKING AND REPLACING ALTERNATOR BELT

• Special tools are required for the replacement of the belt. Ask your Komatsu distributor to perform this work.
• Since the auto-tensioner is installed, tension adjustment is not required.

If alternator drive belt shows the following conditions, it must be

replaced. Ask your Komatsu distributor to replace it.
• When vertical flaw (2) that crosses horizontal flaw (1) is
found.
• When a part of the belt has tears (3).
• You do not need to replace the belt when it has only hori-
zontal flaw (4).

EVERY 2000 HOURS MAINTENANCE

Maintenance for every 50, 100, 250, 500, and 1000 hours service should be performed at the same time.

METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC

TANK STRAINER
k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in-
jury. Wait for the temperature to go down, and then start the work.
• When removing the oil filler cap, the oil may spurt out. Turn it slowly to release the internal pres-
sure, then remove it carefully.

Refill capacity: 92 ℓ
Items to be prepared
• Container to catch the drained oil
1. Lower the bucket to the ground with its bottom level, apply the parking brake, then stop the engine.
2. Remove the bolts (1) (2 pieces) and remove the cover (2).

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MAINTENANCE PROCEDURE MAINTENANCE

3. Remove the cap of oil filler port (F).

4. Place a container under the drain plug (3) to catch the

drained oil.
5. Remove the drain plug (3).
6. Open the drain valve (4) gradually to drain the oil.
7. After draining the oil, close the drain valve (4) and tighten
the drain plug (3).
Tightening torque
Drain plug (3): 29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}
Drain valve (4): 63.7 ± 14.7 Nm {6.5 ± 1.5 kgm}
8. Remove the bolts (5) (2 pieces) and remove the cover (6).

9. Remove the bolts (7) (4 pieces) and remove the cover (8).

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MAINTENANCE MAINTENANCE PROCEDURE

10. Remove the bolts (9) (4 pieces) and remove the cover
(10).
11. Hold the top of rod (11) and pull it up to take out the strain-
er (12).
12. Remove any dirt stuck to the strainer (12), then wash it in
flushing oil.
If the strainer (12) is damaged, replace it with a new one.
13. Install the strainer (12) to the inside of the tank.
14. While pressing the cover (10), tighten the mounting bolts
(9) evenly.
When doing this, if the O-ring (13) of the cover is damaged
or deteriorated, replace it.
15. Refill with the specified quantity of hydraulic oil through oil
filler port (F), then install the cap.

16. Check the hydraulic oil level.

If the oil level is between H and L of sight gauge (G), it is
proper.
17. Run the engine at low idle, and extend and retract each of
the steering, bucket, and boom cylinders 4 to 5 times, tak-
ing care not to move them to the stroke end (stop them ap-
proximately 100 mm short of the stroke end).
NOTICE
If the engine is run at high speed immediately after the
startup or a cylinder is pushed up to its stroke end, air
taken inside the cylinder may cause damage to the
piston packing, etc.
18. Extend and retract each of the steering, bucket, and boom
cylinders to the stroke end 3 to 4 times.

19. Stop the engine, then loosen the cap of the oil filler port
(F).
20. Bleed air from the hydraulic tank. After bleeding air, tighten
the cap of the oil filler port (F).
21. Bleed air while running the engine at low idle.
22. Check the hydraulic oil level.
If the oil level is between H and L of sight gauge (G), it is
proper.
23. Increase the engine speed, and extend and retract each of
the steering, bucket, and boom cylinders 4 to 5 times, tak-
ing care not to move them to the stroke end (stop them approximately 100 mm {3.9 in}  short of the stroke
end).

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MAINTENANCE PROCEDURE MAINTENANCE

Repeat this work until no air is discharged from the oil filler port (F).
24. Stop the engine.
25. Check the hydraulic oil level approximately 5 minutes later.
If the oil level is between H and L of sight gauge (G), it is proper.
26. Check the cover (10) mount for oil leakage.
27. Install the cover (8) with bolts (7) (4 pieces).

28. Install the cover (6) with bolts (5) (2 pieces).

29. Install the cover (2) with bolts (1) (2 pieces).

METHOD FOR REPLACING HYDRAULIC OIL FILTER CARTRIDGE

k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in-
jury. Wait for the temperature to go down, and then start the work.
• When removing the oil filler cap, the oil may spurt out. Turn it slowly to release the internal pres-
sure, then remove it carefully.

Items to be prepared
• Container to catch the drained oil
• Filter wrench

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MAINTENANCE MAINTENANCE PROCEDURE

1. Remove the bolts (1) (4 pieces) and remove the cover (2).

2. Place a container to catch the drained oil under the filter

cartridge (3).
3. Turn the filter cartridge (3) counterclockwise by using the
filter wrench, and remove it.
4. Clean the filter head.
5. Fill the new filter cartridge with clean oil, coat the seal sur-
face and thread portion with clean oil (or thinly apply the
grease to it), then install the filter cartridge.
Tightening torque : 54 to 66 Nm {5.5 to 6.7 kgm}
6. Install the cover (2) with bolts (1) (4 places).
7. Check the hydraulic oil level.
If the oil level is between H and L of sight gauge (G), it is
proper.
8. If it is below the L level, refill the hydraulic oil according to
the following procedure.

1) Remove the bolts (4) (2 pieces) and remove the cover

(5).

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MAINTENANCE PROCEDURE MAINTENANCE

2) Add the hydraulic oil through oil filler port (F).

3) Install the cover (5) with bolts (4) (2 pieces).

9. Check the hydraulic oil filter for oil leakage.

METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT

k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in-
jury. Wait for the temperature to go down, and then start the work.
• When removing the oil filler cap, the oil may spurt out. Turn it slowly to release the internal pres-
sure, then remove it carefully.

1. Remove the bolts (1) (2 pieces) and bolts (2) (2 pieces),

then remove the covers (3) and (4).

2. Remove the bolts (5) (4 pieces) and remove the cover (6).
3. Before removing the breather, wipe off dirt and dusts
around it.

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MAINTENANCE MAINTENANCE PROCEDURE

4. Remove the cap of oil filler port (F).

5. Remove the snap ring (8) of breather (7), remove the
breather cap (9), and replace filter element (10) with a new
one.
6. Install the breather cap (9) and snap ring (8).
7. Close the cap of oil filler port (F).
8. Install the cover (6) with bolts (5) (4 pieces).
9. Install the covers (3) and (4) with bolts (1) (2 pieces) and
bolts (2) (2 pieces).

METHOD FOR CHANGING OIL IN AXLE CASE

k WARNING
• When changing the oil, apply the parking brake and secure the front and rear frames with the frame
lock bar.
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in-
jury. Wait for the temperature to go down, and then start the work.
• If the plug is removed, oil may spurt out, so turn it slowly to release the internal pressure, then re-
move it carefully.

Refill capacity
Front: 27 ℓ
Rear: 25.5 ℓ
Items to be prepared
• Container to catch drained oil
A: Front, B: Rear

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MAINTENANCE PROCEDURE MAINTENANCE

1. Place a container under drain plug (P) to catch the drained

oil.
2. Remove front and rear plugs (1), then remove drain plug
(P) to drain the oil.
REMARK
Remove the mud and dirt from around plug (1), then re-
move the plug.
3. After draining the oil, clean and install drain plug (P).
4. Add the refill capacity of oil through plug hole (1).
REMARK
Be careful that the amount of the lubricating oil for the axle
with Limited Slip Differential may be different. Always use
the specified lubricating oil.

5. Wipe off oil of dipstick (G) installed to plug (1) by using a

piece of cloth.
6. Set dipstick (G) as shown in the figure.
(2): Axle
(3): Spot facing surface
7. Check the oil level.
The oil level is appropriate if it is between 2 grooves (H)
and (L) of the dipstick.
8. If the oil does not reach the lower groove (L), supply the
axle oil from oil filler port (F).
9. If the oil level exceeds the upper groove (H), drain the ex-
cessive oil through the drain plug (P), and then check the
oil level again.
10. If the oil level is appropriate, install plug (1).
Tightening torque: 93 to 123 Nm {9.5 to 12.5 kgm}
REMARK
When the given work requires to use the brake more fre-
quently than usual, replace the axle oil earlier than the
usual timing.

METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC AIR FILTERS

Remove both the recirculation air filter and fresh air filter in the same way as in the cleaning procedure, and
replace them with new ones.

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METHOD FOR CLEANING BRAKE CIRCUIT STRAINER

k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in-
jury. Wait for the temperature to go down, and then start the work.
• When removing the rubber hose, the oil may spurt out. Turn it slowly to release the internal pres-
sure, then remove it carefully.

Items to be prepared
• Container to catch the drained oil
1. Remove the bolts (1) (3 pieces) and remove the rear frame
cover (2).

2. Remove the bolts (3) (3 pieces), and remove the washer

tank cover (4).

3. Remove the washer hose connectors (5) (2 places) and

washer tank harness connectors (6) (2 places).

4. Remove the bolts (7) (4 pieces), and remove the washer

tank assembly (8).

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MAINTENANCE PROCEDURE MAINTENANCE

5. Place a container under the rubber hose (9) and flange

(10) to catch the drained oil.
6. Remove the rubber hose (9) and flange (10).

7. Take out the strainer (11) and wash it in the clean diesel
fuel.
8. Install the strainer (11) into strainer case (13) with the pro-
trusion (O-ring) side toward you, and install it with flange
(12).
9. Install the rubber hose (9).
10. Install the washer tank assembly (8) with bolts (7) (4
pieces).
11. Install the washer hose connectors (5) and washer tank
harness connectors (6).
12. Install the washer tank cover (4) with bolts (3) (3 pieces).
13. Install the rear frame cover (2) with bolts (1) (3 pieces).

METHOD FOR CHECKING BRAKE DISC WEAR AMOUNT

k WARNING
• When checking the condition, apply the parking brake and fix the front and rear frames by using the
frame lock bar.
• Perform this check when the brake oil temperature is 60 °C or below.
• If the disc wear approaches the wear limit, check the condition frequently, regardless of the mainte-
nance interval.

Inspection of wear on the brake disc must be done for 4 places, namely on both sides of the front and rear axle.
Perform the inspection in same procedure for all of them.
1. Remove cap nut (1).

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MAINTENANCE MAINTENANCE PROCEDURE

2. Push in rod (2) fully while depressing the brake pedal.

The amount of the protrusion of rod end face (C) from
guide end face (D) corresponds to wear amount (A).
Measure the protrusion.
Allowable disc wear limit (B) corresponds to the distance
between groove (E) and end face (D) of the guide.
In such case, ask your Komatsu distributor to perform in-
spection and replacement of the part.
If the disc wear approaches the wear limit, check the con-
dition frequently, regardless of the maintenance interval.
3. Install cap nut (1).
Tightening torque: 29.4 to 39.2 Nm {3.0 to 4.0 kgm}
REMARK
• On a new machine, the position of the end face of rod (2) is adjusted so that it matches the end face of
guide (3). Therefore, do not loosen lock nut (4) except when replacing the disc.
• Perform the operation with 2 workers. One worker depresses the brake pedal and the other pushes in
the rod.

METHOD FOR CHECKING FUNCTION OF PPC ACCUMULATOR

For handling of the accumulator, see “HANDLE ACCUMULATOR AND GAS SPRING (2-40)”.
When you cannot restart the stopped engine while the work equipment is raised, you can use, as urgent meas-
ures, the oil pressure stored in the accumulator to actuate the valve, thereby, lower the work equipment to the
ground.
1. Apply the parking brake.
2. Raise the work equipment to the upper end and operate
the multifunction mono-lever to “HOLD” position (b).
3. Stop the engine.
4. Turn the starting switch to ON position.
5. Press the work equipment lock switch and unlock the work
equipment (the pilot lamp goes out).
6. After checking safety around the machine, operate the
multifunction mono-lever to “FLOAT” position (d) and lower
the work equipment to a position 1 m from the ground.
7. After the work equipment is lowered to a position 1 m from
the ground, return the multifunction mono-lever to “LOW-
ER” position and lower the work equipment gradually to
the ground.
REMARK
The check must be done within 2 minutes after the engine
stops. If the engine is kept stopped, the gas pressure in
the accumulator lowers and the inspection cannot be
made.
If the work equipment stops halfway, the accumulator gas pressure may be low.
Ask your Komatsu distributor for inspection.
Replace the accumulator for every 4000 hours or every 2 years.

METHOD FOR CHECKING ALTERNATOR

Ask your Komatsu distributor to have the alternator checked.
If the engine is started frequently, have this inspection performed every 1000 hours.

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METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE

Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work.

METHOD FOR CHECKING VIBRATION DAMPER

Check that there are no cracks or peeling in the outside surface of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.

METHOD FOR REPLACING KCCV FILTER ELEMENT

k WARNING
Immediately after the engine is stopped, all the parts are still very hot. Do not replace the filter element
immediately. Wait for all parts to cool down before starting the work. Always stop the engine before
starting the replacement work.

NOTICE
• Komatsu recommends using Komatsu genuine parts for replacement parts.
• If the engine is operated without the filter element, the turbocharger and aftercooler become dirty
and their performance will lower and it can cause engine problems such as overrun caused by suc-
tion of oil. Never try such practice.
• The filter element cannot be cleaned. Flushing or regenerating of the filter element will degrade per-
formance of the filter. As a result, the turbocharger and aftercooler become dirty and the perform-
ance lowers or the crankcase pressure increases. Never reuse the filter element since it can cause
an engine failure.
• After the filter element is replaced, if KCCV is not assembled correctly, oil or blowby gas may leak.
Replace the filter element in the correct procedure.
Items to be prepared
• Container to catch the drained oil
• Special wrench for KCCV
The KCCV ventilator is located in the position shown in the fig-
ure.

For the use of the special wrench, see the figure.

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MAINTENANCE MAINTENANCE PROCEDURE

1. Remove the bolt (1), then remove the fixing clip (2) of the
KCCV drain hose.

2. By using the special wrench, loosen the ring (5) of the

KCCV ventilator (3).

3. After the ring (5) comes off, remove the case (6) from body (4), and remove the element (7).
There may be oil accumulated or sticking in the case and
element. Take care not to spill the oil when replacing the
element.
REMARK
When the ambient temperature is low, water or emulsified
matter may stick to the inside of KCCV because of con-
densation of water vapor in the blowby gas. However, if
the coolant level is normal, it is not a problem.

4. Remove the used O-ring (8) sticking to the case (6) and install a new O-ring contained in the service kit.
Apply the engine oil to the new O-ring.

5. While matching the ◇ mark (9) of the new element with the
◇ mark (10) of the body label, insert the element firmly into
the end of the body.

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MAINTENANCE PROCEDURE MAINTENANCE

The element can be installed only when its claws (11) are
correctly inserted in grooves (12) of the filter body. Bases
(13) and (14) are oval. When inserting, take extreme care
so that those bases are matched with each other.

6. Align the position of ◇ mark (15) on the case with that of ◇

mark (10) of the filter body label, then install the case to
the filter body.

The case can be installed only when its claws (16) are cor-
rectly inserted in grooves (12) of the filter body. When in-
serting, take extreme care so that the protrusion (17) in the
case is joined together with the rubber lip (18) of the ele-
ment.

7. Fit the ring (5) to the threaded part of the body and tighten
it with hands firmly until it stops.

8. Tighten the ring 1/15 to 2/15 turns further (1 to 2 ridges of

the ring) by using the special wrench.
If the engine is operated with the ring tightened insufficient-
ly, oil and blowby gas may leak.
9. Install the bolt (1) which has been removed in the step 1,
and restore the KCCV drain hose.

Check the KCCV hose for leakage, crack, and loose clamp, and replace it if necessary.

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MAINTENANCE MAINTENANCE PROCEDURE

METHOD FOR REPLACING DEF FILTER

k WARNING
Immediately after the engine is stopped, the parts are still very hot. Do not replace the filter immediately.
Wait until all of parts cool down before starting the work.

NOTICE
• Komatsu recommends using Komatsu genuine parts for replacement parts.
• If the machine is operated without DEF filter attached, or with the filter other than Komatsu genuine
parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the
machine. Never operate the machine without DEF filter attached, nor use the filter other than Komat-
su genuine parts.
• DEF filter cannot be flushed. Flushing or regenerating of it will degrade the performance of filter,
and will cause the breakage of DEF tank. Never reuse the DEF filter.
• Improper assembly of DEF filter may cause leakage of DEF. Replace the DEF filter in the correct pro-
cedure.
• DEF freezes at –11 °C. If it is frozen, replacement of the filter becomes difficult. Replace the filter
when the temperature around DEF pump is higher than -11 °C, and in the condition that DEF is not
frozen.
After the engine is stopped, DEF system devices automatically purge DEF in DEF injector and DEF pump and
return it to DEF tank to prevent malfunction of the devices caused by freezing of DEF or deposition of urea.
After the engine is stopped, the devices are operated for a few minutes. Before replacing the filter, clean around
the DEF pump first after DEF system devices stop.
Items to be prepared
• DEF filter removal tool
• Torque wrench
1. Remove the bolts (1) (6 pieces) to remove cover (2).

The DEF filter is located at the positions shown in the fig-

ure.

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MAINTENANCE PROCEDURE MAINTENANCE

2. Remove filter cap (3) at the bottom of DEF pump, and re-
move equalizing element (4).

3. Turn cap (6) of filter removal tool (5) and remove it.
4. Check the installation of spacer (7).

5. Insert filter removal tool (5) into the bottom of the DEF
pump and thrust in with hand.

6. Check that filter removal tool (5) is fully inserted to the end.
Insert the filter to the end where you cannot thrust it in any
further.

7. Turn filter removal tool (5) in reverse, and remove filter (8).
Filter (8) is removed and you can take it out together with
filter removal tool (5).
If filter (8) cannot be removed from DEF pump, grip filter
removal tool (5), pull it down, then it will be removed.

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MAINTENANCE MAINTENANCE PROCEDURE

8. Slide filter (8) down, and remove spacer (7) from filter re-
moval tool (5).

9. Pull filter (8) up while pushing in the tip of filter removal

tool (5), and remove it.
10. Return the removed spacer (7) to filter removal tool (5),
and keep them.
11. Insert a new filter and a new equalizing element into the
bottom of DEF pump, and lightly tighten them with hand.

12. Tighten filter cap (3).

Tightening torque: 20 to 25 Nm {2.0 to 2.5 kgm}
13. Install cover (2) with bolts (1) (6 pieces).

METHOD FOR REPLACING DEF TANK BREATHER ELEMENT

k WARNING
Do not replace the element immediately after engine is stopped.

NOTICE
• Komatsu recommends using Komatsu genuine parts for replacement parts.
• If the machine is operated without DEF tank breather element attached, or with the element other
than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which
will cause failure of the machine. Never operate the machine without DEF tank breather element at-
tached, nor use the element other than Komatsu genuine parts.
• Do not flush DEF tank breather element. Flushing or regenerating of it will degrade the performance
of element, and will cause the breakage of DEF tank. Never reuse the DEF element.
• Always stop the engine and clean around DEF tank before replacing.
• After the engine is stopped, DEF system devices automatically purge DEF in DEF injector and DEF
pump and return it to DEF tank to prevent malfunction of the devices caused by freezing of DEF or
deposition of urea.
After the engine is stopped, the devices are operated for a few minutes. Replace the element after
DEF system devices stop.
• Improper assembly of DEF tank breather element may cause leakage of DEF. Replace the element in
the correct procedure.

4-79
MAINTENANCE PROCEDURE MAINTENANCE

1. Remove bolts (1), and remove cover (2).

2. Remove nut (4) of breather assembly (3) at the top of DEF

tank, then remove cover (5).
3. Replace breather (6) with a new one.
When installing breather element (6), direct the surface of
TOP mark (7) towards up and install.
4. Install cover (5) and nut (4).
5. Install cover (2) with bolt (1).

EVERY 4000 HOURS MAINTENANCE

Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours service should be performed at the same time.

REPLACE DEFINED LIFE PARTS

Material quality of these parts can change as time passes and they are likely to wear out or deteriorate.
Replace them every 2 years or every 4000 hours, whichever comes sooner.

4-80
MAINTENANCE MAINTENANCE PROCEDURE

DEFINED LIFE PARTS LIST

No. Periodical replacement parts
1 Fuel system Fuel hose
Spill hose
2 Steering system High pressure circuit hose
3 Brake system Brake oil pressure hose
4 Torque converter, trans-
HST circuit hose
mission system
5 Work equipment hydraulic Main pump delivery hose
system
Main pump delivery hose other than described
above
Ask your Komatsu distributor
Main pump LS hose for replacement.
Hydraulic drive fan hose (Exhaust fan)
External work equipment hose
• Lift cylinder hose
• Bucket cylinder (bottom) hose
• Bucket cylinder (head) hose
• Main valve hose
• Quick coupler hose
6 Others PPC accumulator

METHOD FOR LUBRICATING DRIVE SHAFT

Use the special grease for drive shaft, and perform greasing every 4000 hours or every 2 years.
If the special grease is not used but common lithium base grease is used, perform greasing every 1000 hours
after then.
Part No. of special grease for drive shaft: 56B-20-19910
1. By using a grease pump, pump in grease through the grease fittings shown by arrows.
2. After greasing, wipe off any old grease that is pushed out.
(1) Front drive shaft (2 places)

4-81
MAINTENANCE PROCEDURE MAINTENANCE

(2) Rear drive shaft (2 places)

(3) Drive shaft spline (1 place)

METHOD FOR CHECKING WATER PUMP

Check for leakage of water and oil around the water pump. If any problem is found, ask your Komatsu distributor
to perform disassembly, repair, or replacement.

METHOD FOR CHECKING STARTING MOTOR

Ask your Komatsu distributor to have the starting motor checked.
If the engine is started frequently, have this inspection performed every 1000 hours.

METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR

Ask your Komatsu distributor to perform the work.

METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH-PRESSURE PIP-

ING CLAMP, HARDENING OF RUBBER

4-82
MAINTENANCE MAINTENANCE PROCEDURE

Check visually and touch by hand to check that there is no hardening of the rubber and no loose bolts of the
mounting clamps (2 places) for the high-pressure piping between the supply pump and the common rail.
Replacement of the high-pressure piping must be made as an assembly.
If there are any problems, the parts must be replaced. Ask your Komatsu distributor for replacement.

METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP,

HARDENING OF RUBBER
The fuel spray prevention caps on the fuel injection piping and both ends of the high-pressure piping act to pre-
vent the fuel from coming into contact with high-temperature parts of the engine and causing a fire if the fuel
should leak or spray out.

Check fuel spray prevention caps (14 places) visually or with a finger to see if any of them has fell off, or the
rubber portion is hardened.
If there are any problems, the related parts must be replaced. Ask your Komatsu distributor for replacement.

METHOD FOR CHECKING WEAR OF DAMPER GEAR

Checking is not necessary for initial 4000 hours.
Ask your Komatsu distributor for checking the wear amount of damper gear.

EVERY 4500 HOURS MAINTENANCE

Maintenance for every 50, 100, 250 and 500 hours service should be performed at the same time.

METHOD FOR CLEANING KDPF

Contact your Komatsu distributor for cleaning of the KDPF.

METHOD FOR CLEANING DEF TANK

Ask your Komatsu distributor for cleaning of the DEF tank.

EVERY 8000 HOURS MAINTENANCE

Maintenance for every 50, 100, 250, 500, 1000, 2000 and 4000 hours service should be performed at the same
time.

METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP

Ask your Komatsu distributor for replacement of the fuel spray prevention caps.

METHOD FOR REPLACING STARTING MOTOR

(For the machines equipped with the auto idle stop function)
Ask your Komatsu distributor for replacement of the starting motor.

4-83
MAINTENANCE PROCEDURE MAINTENANCE

EVERY 9000 HOURS MAINTENANCE

Maintenance for every 50, 100, 250, 500, 1000 and 4500 hours service should be performed at the same time.

METHOD FOR REPLACING DEF HOSE

Ask your Komatsu distributor for replacement of the DEF hose.

END OF SERVICE LIFE

• For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor.

4-84
SPECIFICATIONS

5-1
SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS
SPECIFICATIONS: WA320-8
Item Unit WA320-8
Operating weight
 kg 15300
(with bolt on cutting edge (BOC))
Normal load  kg 4480
Bucket capacity Heaped  m3 2.8
Engine model - KOMATSU SAA6D107E-3
SAE J1995 (gross) 127 {170} / 2100 {2100}
ISO 14396 kW {HP} / 127 {170} / 2100 {2100}
Rated horsepower
min-1 {rpm}
ISO9249 / SAE
123 {165} / 2100 {2100}
J1349 (net)
A Overall length  mm 7755
B Overall height (work equipment)  mm 3200
C Overall height with bucket lifted up  mm 5375
D Overall width  mm 2590
E Min. ground clearance  mm 425
F Bucket width  mm 2740
Dumpling clearance Cutting edge [BOC
G  mm 2970 [2880]
(*1) tip]
Cutting edge [BOC
H Dumpling reach (*1)  mm 960 [1000]
tip]
I Bucket dump angle(max. height)  ° 47
Cutting edge [BOC
 mm 6275 [6310]
tip]
Min. turning radius
Center of outside
 mm 5380
tire
Permissible towing load  kN { kg}  113 {11475}
1st  km/h 1.0 to 13.0
2nd  km/h 13.0
Forward
3rd  km/h 18.7
4th  km/h 38.0
Max. speed
1st  km/h 1.0 to 13.0
2nd  km/h 13.0
Reverse
3rd  km/h 18.7
4th  km/h 38.0

5-2
SPECIFICATIONS SPECIFICATIONS

*1: Value when bucket dump angle is 45 °.

I
C
H

B
G

F A

9 J W0 1 4 5 6

5-3
ATTACHMENTS AND OP-
TIONS

Please read and make sure that you understand the SAFETY section before
reading this section.

6-1
BUCKET AND TIRE SELECTION ATTACHMENTS AND OPTIONS

BUCKET AND TIRE SELECTION

Select the most suitable bucket and tires for the type of the work and condition of the job site.
Type of operation Bucket Ground conditions Tires
20.5R25☆ (L3: Rock)
General ground
20.5-25-12PR (L3: Rock)
Loading and carrying of Light material bucket
Well-maintained 20.5R25☆ (L3: Rock)
products (with BOC)
ground 20.5-25-12PR(L2: Traction)
Soft ground 20.5-25-12PR(L2: Traction)
20.5R25☆ (L3: Rock)
General ground
Loading of products and Excavating bucket 20.5-25-12PR (L3: Rock)
blasted rock (with BOC) 20.5R25☆ (L3: Rock)
Hard ground
20.5-25-12PR (L3: Rock)

BOC: Abbreviation for Bolt On Cutting edge

You need to change the travel speed display on the machine monitor according to the tire size. If you are instal-
ling the optional tires, ask your Komatsu distributor for installation.

6-2
ATTACHMENTS AND OPTIONS HANDLE JOYSTICK STEERING SYSTEM

HANDLE JOYSTICK STEERING SYSTEM

Read thoroughly for safe and effective use of joystick steering before using it.

EXPLANATION OF COMPONENTS IN JOYSTICK STEERING SYSTEM

(1) Joystick ON/OFF switch (6) Wiper switch

(2) Joystick directional selector switch (7) Armrest adjuster knob
(3) Joystick steering lever activator switch (8) Armrest left-right position adjuster lever
(4) Joystick activation switch (9) Joystick console fore-aft adjustment knob
(5) Horn switch (10) Control panel position adjuster lever

6-3
HANDLE JOYSTICK STEERING SYSTEM ATTACHMENTS AND OPTIONS

JOYSTICK ON/OFF SWITCH

When the joystick ON/OFF switch is turned to ON position, joy-
stick steering lever activation switch, horn and wiper knob, and
joystick directional selector switch are effective.
Position (a): ON (joystick steering armrest is effective)
Position (b): OFF (joystick steering armrest is not effective)

JOYSTICK DIRECTIONAL SELECTOR SWITCH

k WARNING
Do not maintain the joystick directional selector switch at the intermediate position between positions
(F) and (N), or between positions (N) and (R). The alarm buzzer sounds and the transmission is set in
NEUTRAL.

The joystick directional selector switch is used to set the travel

direction to FORWARD, NEUTRAL, or REVERSE.
Position (F): FORWARD
Position (N): NEUTRAL
Position (R): REVERSE

Before using this switch to change the travel direction, set the
directional lever to NEUTRAL position and set the directional
selector enable switch of R.H. switch panel to position (b).

JOYSTICK ACTIVATION SWITCH

The joystick activation switch is used to activate the joystick steering.
The joystick pilot lamp on the activation switch lights up as long as the joystick steering is selected.

6-4
ATTACHMENTS AND OPTIONS HANDLE JOYSTICK STEERING SYSTEM

To activate the joystick steering:

• The joystick ON/OFF switch must be switched ON
• The joystick console must be lowered.

JOYSTICK STEERING LEVER

The joystick steering lever is used to steer the machine.
Tilt the lever in the direction of the turn during traveling, then
the machine turns.
(a): Left turn
(b): Right turn
(N): NEUTRAL

HORN SWITCH
The horn switch is located at the head of the joystick steering lever.
If you press the horn switch, the horn sounds.
You can sound the horn without releasing your hand from the
lever by using the horn switch.

WIPER SWITCH
If you press the wiper switch, the front wiper moves.

JOYSTICK CONSOLE LIFT UP

Position (a): Joystick steering system operates.

6-5
HANDLE JOYSTICK STEERING SYSTEM ATTACHMENTS AND OPTIONS

Position (b): Joystick steering system does not operate. (Sys-

tem is turned OFF.)

JOYSTICK CONSOLE FORE-AND-AFT POSITION ADJUSTER KNOB

The joystick console fore-aft adjustment knob is used to move
the whole joystick console forward or backward.
For details, see "METHOD FOR ADJUSTING JOYSTICK
CONSOLE".

ARMREST ADJUSTER KNOB

You can move the armrest up and down by turning the armrest adjustment knob.
When you lift up the angle of the armrest for more than 5 ° , the
joystick steering is deactivated.

6-6
ATTACHMENTS AND OPTIONS HANDLE JOYSTICK STEERING SYSTEM

Also, you can adjust the angle of the armrest.

CONTROL PANEL POSITION ADJUSTER LEVER

The control panel adjustment lever are used to move the whole joystick control panel in up, down, left or right
position.
For details, see "METHOD FOR ADJUSTING JOYSTICK
CONSOLE”.

JOYSTICK PILOT LAMP

The joystick pilot lamp lights up, when the joystick activation switch is pushed and the joystick console is low-
ered and the joystick switch is in ON position.
For details, see "JOYSTICK ON/OFF SWITCH".

ARMREST LEFT-RIGHT POSITION ADJUSTER LEVER

You can move the armrest to the right and left by loosening the
armrest right-left adjustment lever.

6-7
HANDLE JOYSTICK STEERING SYSTEM ATTACHMENTS AND OPTIONS

FUNCTION AND STRUCTURE OF JOYSTICK STEERING SYSTEM

Joystick steering system is a device to perform steering of
wheel loader by lever operation of joystick instead of steering
wheel. With joystick, steering operation can be performed by
light effort and small stroke which reduces steering operation.
Push the joystick activation switch, then steering operation with
joystick becomes effective.
The joystick pilot lamp on the left arm-rest lights up as long as
the joystick steering is selected.
On machines equipped with joystick steering system, you can
select of steering operation and transmission operation with the
joystick switch as shown below.
There are differences in function between the joystick steering lever operation and steering wheel operation.
Selection Joystick steering lever operation Steering wheel operation
Joystick activation switch Lights up Do not light
Steering Both of joystick steering lever opera- Only steering wheel operation is ena-
tion and steering wheel operation are bled
enabled. If both are operated simulta-
neously, steering wheel operation is
given priority.
Transmission Directional selec- Joystick directional selector switch Transmission directional lever opera-
tion operation is enabled tion is enabled
Travel speed con- • When joystick ON/OFF switch
trol function is turned ON, maximum speed
on a level ground is limited ap-
proximately to 18 km/h auto- None
matically.
• The machine may not travel at
4th speed.

PRECAUTIONS FOR HANDLING JOYSTICK STEERING SYSTEM

k WARNING
• The joystick console must be at lower rear position during operation even when joystick steering is
not used. At this time, be sure to set the joystick ON/OFF switch to OFF position.
• Never use joystick steering when traveling on public road.
• Use steering wheel when the travel speed is 20 km/h or higher, or when traveling on public road.
When operating the machine by using the steering wheel, set the joystick ON/OFF switch to OFF
position.
• When driving the machine by using joystick steering lever and when operating the transmission,
the machine may not go along with the operation. At that time, operate the steering wheel to move
the machine to a safe place and stop the machine, then turn the joystick ON/OFF switch to OFF po-
sition.
Then ask your Komatsu distributor for repair.
• Never get on and operate the machine which is not repaired completely.

• The steering wheel operation is always prior to the joystick steering.

• When turning the machine, if you operate the steering wheel, the machine stops articulation at the position
where you stop turning the steering wheel. However, if you tilt the joystick and hold it at the position, the
machine articulates to the end, so be careful.

6-8
ATTACHMENTS AND OPTIONS HANDLE JOYSTICK STEERING SYSTEM

Since the operation feeling is different from the steering wheel, be careful when operating joystick steering.
• When the joystick steering can not be activated, if the directional lever and joystick directional selector
switch are not in NEUTRAL position (N).
Temporarily return the directional lever and the joystick directional selector switch to NEUTRAL position (N).
• When the electrical circuits of joystick steering system and transmission control system have trouble, the
centralized warning lamp (red) lights up to inform the operator about the trouble.
Since both steering and transmission are set in NEUTRAL position (N), turn the joystick ON/OFF switch to
OFF position, then operate the machine by using the steering wheel and the directional lever.

METHOD FOR HANDLING JOYSTICK STEERING SYSTEM

k WARNING
• Avoid joystick steering operation during high-speed travel or on a steep slope.
• When turning the machine, if you operate the steering wheel, the machine stops articulation at the
position where you stop turning the steering wheel. However, if you tilt the joystick steering lever
and hold it at the position, the machine articulates to the end, so be careful.
• Since the operation feeling is different from the steering wheel, be careful when operating the joy-
stick steering.
• When moving the directional lever of the steering wheel to F or R position while the joystick
ON/OFF switch is in ON position, the machine travels forward or in reverse in according with the
directional lever regardless of the position of directional selector switch on the joystick steering
lever.
Be careful to operate because the directional lever operation of the steering wheel is prior.
• In this case, the centralized warning lamp lights up and alarm buzzer sounds.
• Stop the machine and set the directional lever and the directional selector switch on the joy-
stick steering lever to N position.

Perform checks and adjustment before starting the engine. For details, see “CHECKS AND ADJUSTMENT BE-
FORE STARTING ENGINE”.
1. Before starting the engine, check the steering performance
of the joystick steering lever, check that the directional lev-
er is in NEUTRAL position (N) and the surrounding area is
safe.
REMARK
If the machine is under the following condition when start-
ing the engine, an alarm may be issued.
• When the directional selector switch on the joystick
steering lever is in F or R, the centralized warning
lamp lights up, and alarm buzzer sounds.
The engine does not start under this condition. Set di-
rectional selector switch to NEUTRAL position (N).
• When the joystick steering lever is not in the neutral
position, the alarm buzzer sounds.
The engine does not start under this condition. Set the
joystick steering lever to NEUTRAL position.

6-9
HANDLE JOYSTICK STEERING SYSTEM ATTACHMENTS AND OPTIONS

2. Press (a) on the joystick ON/OFF switch to turn ON.

3. The machine turns to the right when you tilt the joystick
steering lever toward (b) and to the left when you tilt it to-
ward (a).
The larger the joystick steering lever tilts, the faster the ar-
ticulation speed becomes.
4. When the articulation angle reaches the desired level, re-
turn the joystick steering lever to NEUTRAL position (N).
The joystick steering lever returns automatically to NEU-
TRAL position (N).
5. In order to return the machine to the straight travel, tilt the
joystick steering lever from NEUTRAL position (N) in the
opposite direction to which the machine has been turned (i.e. to the left when it has been turned to the
right).
6. Switch the forward and reverse travel of transmission by
using the directional selector switch on the top of the joy-
stick steering lever.
Position F: FORWARD
Position N: NEUTRAL
Position R: REVERSE
When the position of the directional lever is different from
that of the directional selector switch on the joystick steer-
ing lever, the centralized warning lamp lights up, and alarm
buzzer sounds.
In this condition, the machine travels forward and reverse in accordance with the directional lever position.
Set the directional lever to NEUTRAL position (N).
7. Press (b) on the joystick ON/OFF switch to turn OFF.
The joystick operation is released.

6-10
ATTACHMENTS AND OPTIONS HANDLE JOYSTICK STEERING SYSTEM

SELECTION OF OPERATION WITH JOYSTICK STEERING LEVER AND

STEERING WHEEL
k CAUTION
Switching operation of transmission forward and reverse travel control (switching from directional lever
to joystick directional selector switch while joystick ON/OFF switch is ON, or switching from joystick di-
rectional selector switch to directional lever while joystick ON/OFF switch is OFF) can only be available
when the directional lever and the joystick directional selector switch are in NEUTRAL position (N). If
those lever and switch are not in NEUTRAL position (N), the centralized warning lamp lights up, and the
alarm buzzer sounds.
Temporarily return the directional lever and the joystick directional selector switch to NEUTRAL posi-
tion (N).

Select suitable operation from joystick steering lever operation and steering wheel operation in accordance with
the work.
• Steering by joystick steering lever operation
This operation is suitable for the continuous loading work in a broad work place under slow cycle time.
Since the operation with less stroke and less operating effort is available, fatigue in continuous operation
decreases.
• Steering by steering wheel operation
This operation is suitable for travel between job sites and load-and-carry operation, since high-speed
straight travel performance and lifting operation performance are high in it.
• The maximum speed on a level ground is limited approximately to 18 km/h automatically.

METHOD FOR GETTING ON OR OFF TO OPERATOR'S CAB

k WARNING
Set the joystick ON/OFF switch to OFF position, keep the joystick console upward when getting on or
off the operator's seat.
When the console lock release lever is pulled up and the joystick console is moved upward, the power
supply for the joystick steering system is turned OFF, then joystick becomes inoperable.

You can spring up the joystick console so that the getting on or off the operator's seat becomes easy.
If you move the joystick steering lever carelessly while engine is running, the machine may articulate unexpect-
edly and it may be dangerous. To avoid this, be sure to set the joystick ON/OFF switch to OFF position when
the machine is not operated.
1. Set joystick ON/OFF switch to OFF position (b)
The power supply becomes OFF and the joystick steering
system does not operate.
2. When you operate the machine, be sure to lower the joy-
stick console first and then set joystick ON/OFF switch to
ON position (a).
The power supply becomes ON and the joystick steering
system operates.

6-11
HANDLE JOYSTICK STEERING SYSTEM ATTACHMENTS AND OPTIONS

METHOD FOR ADJUSTING JOYSTICK CONSOLE

k WARNING
• Perform adjustment after placing the machine in a level and safe place.
• Adjust it before starting operation or when operators change shift.
• Adjust the operator's seat so that you can depress the brake pedal fully when you are sitting with
your back contacted to backrest of operator's seat, and adjust the console.
• Tighten the knob completely after performing fore-and aft adjustment of joystick console.

• Lower the joystick console and loose up-down adjustment

knob (1) to adjust the height of it.

• Adjust the angle of the armrest by loosing lever (2).

6-12
ATTACHMENTS AND OPTIONS HANDLE JOYSTICK STEERING SYSTEM

• Adjust the armrest to the right or left by loosening levers

(3) and (4).
• Adjust the armrest to forward or backward in length by
loosing knob (5).
• Adjust control panel (8) by loosing lever (5) and (6) in the
optimal operating position.

6-13
HANDLE HYDRAULIC TYPE QUICK COUPLER ATTACHMENTS AND OPTIONS

HANDLE HYDRAULIC TYPE QUICK COUPLER

k WARNING
Before operating the machine, check that the attachment is correctly connected. If it is not correctly in-
stalled, the attachment may fall off and cause serious injury.
• Check that the quick coupler switch is not in the unlock position, the quick coupler lock release pi-
lot lamp does not light up and the alarm buzzer does not sound intermittently.
• Check that the lock pin indicators on left and right side are visible moved out.

EXPLANATION OF COMPONENTS ON MACHINES WITH QUICK COUPLER

(1) Quick coupler attachment switch
(2) Quick coupler lock release pilot lamp

QUICK COUPLER ATTACHMENT SWITCH

Quick coupler attachment switch is used for coupling the attachment and the coupler or decoupling them when
installing or removing the attachment.
(When the 2-point switch)
The switch automatically returns to its original position when re-
leasing your hand from the switch.
Position (A): Decoupling
Pull the lock (a) in the direction shown by arrow (b) when
pressing the switch into this position.

6-14
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC TYPE QUICK COUPLER

(When the 3-point switch)

The switch automatically returns to NEUTRAL position (N)
when releasing your hand from the switch.
Position (A): Decoupling
Pull the lock (a) in the direction shown by arrow (b) when
pressing the switch into this position.
Position (N): NEUTRAL
Position (B): Coupling
Pull the lock (a) in the direction shown by arrow (b) when push-
ing down the switch to this position.

QUICK COUPLER LOCK RELEASE PILOT LAMP

Quick coupler lock release pilot lamp lights up when the quick
coupler attachment switch is in the position of decoupling.
If this lamp is lit in other time than the decoupling operation of
quick coupler, there is a trouble in quick coupler solenoid ac-
tuating circuit. Move the machine immediately to a safe place,
stop the engine, then perform the inspection.
(When the 2-point switch)
In order to release the quick coupler, operate the multifunction
mono-lever to TILT side while the quick coupler attachment
switch is in the decoupling position.
(When the 3-point switch)
In order to release the quick coupler, operate the quick coupler attachment switch to the decoupling position.

METHOD FOR REMOVING ATTACHMENT

(When the 2-point switch)

k WARNING
Do not perform the decoupling operation of the quick coupler while the work equipment is being dump-
ed. The attachment will come off and fall, and it may lead to a serious personal injury or death.

1. Tilt the attachment.

g0038100

6-15
HANDLE HYDRAULIC TYPE QUICK COUPLER ATTACHMENTS AND OPTIONS

2. While pulling the lock (a) of the quick coupler attachment

switch in arrow direction (b), push it into decoupling posi-
tion (A).
• Keep the quick coupler attachment switch pressed un-
til the work of the step 6 is completed.
• When you release the quick coupler, the quick coupler
lock release pilot lamp (1) lights up, and the alarm
buzzer sounds intermittently.

3. Operate the lever from “HOLD” position (B) to “TILT” posi-

tion (e) while the quick coupler attachment switch is press-
ed into (a). Retract the coupler plunger while keeping it at
“TILT” position (e) from the state that the coupler contacts
to the tilt-end stopper. Release the lock of attachment.

4. Check that the lock pins have been removed. The lock pin
indicators (3) may not be visible.

g0038103

5. Lower the attachment completely to the ground and set it

in a stable position.

g0038104

6-16
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC TYPE QUICK COUPLER

6. Tilt the coupler forward slowly and lower it slowly so that it

separates from the attachment hook.
7. Release the quick coupler attachment after checking that
the coupler is released from attachment hook. Put your
hand off the quick coupler switch.
The switch returns to its original position, the pilot lamp (1)
for releasing quick coupler goes out, and the alarm buzzer
stops sounding.
8. Drive the machine in reverse slowly to separate the ma-
chine from the attachment.

METHOD FOR REMOVING ATTACHMENT

(When the 3-point switch)

k WARNING
Do not perform the decoupling operation of the quick coupler while the work equipment is being dump-
ed. The attachment will come off and fall, and it may lead to a serious personal injury or death.

1. Tilt the attachment.

g0038100

2. While pulling the lock (a) of the quick coupler attachment

switch in arrow direction (b), push it into decoupling posi-
tion (A).
• Keep the quick coupler attachment switch pressed un-
til the work of the step 5 is completed.
• When you release the quick coupler, the quick coupler
lock release pilot lamp (1) lights up, and the alarm
buzzer sounds intermittently.

6-17
HANDLE HYDRAULIC TYPE QUICK COUPLER ATTACHMENTS AND OPTIONS

3. Check that the lock pins have been removed. The lock pin
indicators (3) may not be visible.

g0038103

4. Lower the attachment completely to the ground and set it

in a stable position.

g0038104

5. Tilt the coupler forward slowly and lower it slowly so that it

separates from the attachment hook.
6. Check that the coupler is released from attachment hook.
Put your hand off the quick coupler switch.
The switch returns to NEUTRAL position (N), the quick
coupler release pilot lamp (1) goes out, and the alarm buz-
zer stops sounding.
7. Drive the machine in reverse slowly to separate the ma-
chine from the attachment.

METHOD FOR INSTALLING ATTACHMENT

(When the 2-point switch)
1. Set the coupler tilted forward posture on a level ground,
stop the machine at the position just before attachment
hook and the coupler tube come to the same line.
Depress the brake pedal to stop the machine with direc-
tional lever at forward.

g0038106

6-18
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC TYPE QUICK COUPLER

2. While pulling the lock (a) of the quick coupler attachment

switch in arrow direction (b), push it into decoupling posi-
tion (A).
• Keep the quick coupler attachment switch pressed un-
til the work of the step 8 is completed.
• When you release the quick coupler, the quick coupler
lock release pilot lamp (1) lights up, and the alarm
buzzer sounds intermittently.

3. Operate the lever from “HOLD” position (B) to “TILT” posi-

tion (e) while the quick coupler attachment switch is press-
ed into (A). Retract the coupler plunger while keeping it at
“TILT” position (e) from the state that the coupler contacts
to the tilt-end stopper.

4. Check that the lock pins have been removed. The lock pin
indicators (3) may not be visible.

g0038103

5. Operate the lever from “HOLD” position (B) to “DUMP” po-

sition (f), and set the coupler tilted forward.

6-19
HANDLE HYDRAULIC TYPE QUICK COUPLER ATTACHMENTS AND OPTIONS

6. Raise the coupler slowly as the machine travels forward,

keep raising it until coupler tube comes to be connected
with the attachment hook and the attachment is a little lift-
ed off from the ground.
7. Check that the attachment is horizontal to the left and right
and that each hook is correctly inserted.

8. Operate the lever from “HOLD” position (B) to “TILT” posi-

tion (e), and set the coupler tilted fully.
9. Put your hand off the quick coupler attachment switch.
The switch returns to its original position, the quick coupler
release pilot lamp (1) goes out, and the alarm buzzer stops
sounding.

10. Operate the lever from “HOLD” position (B) to “TILT” posi-
tion (e), and keep it in “TILT” position (e). Pull out the cou-
pler plunger to lock the attachment.

g0038100

11. Check that the lock pin indicators (3) on left and right side
are visible moved out.
12. Check that the quick coupler and the attachment are com-
pletely locked.

g0038108

METHOD FOR INSTALLING ATTACHMENT

(When the 3-point switch)

6-20
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC TYPE QUICK COUPLER

1. Set the coupler tilted forward posture on a level ground,

stop the machine at the position just before attachment
hook and the coupler tube come to the same line.
Depress the brake pedal to stop the machine with direc-
tional lever at forward.

g0038106

2. While pulling the lock (a) of the quick coupler attachment

switch in arrow direction (b), push it into decoupling posi-
tion (A)
• Keep the quick coupler attachment switch pressed un-
til the work of the step 7 is completed.
• When you release the quick coupler, the quick coupler
lock release pilot lamp (1) lights up, and the alarm
buzzer sounds intermittently.

3. Check that the lock pins have been removed. The lock pin
indicators (3) may not be visible.

g0038103

4. Operate the lever from “HOLD” position (B) to “DUMP” po-

sition (f), and set the coupler tilted forward.

6-21
HANDLE HYDRAULIC TYPE QUICK COUPLER ATTACHMENTS AND OPTIONS

5. Raise the coupler slowly as the machine travels forward,

keep raising it until coupler tube comes to be connected
with the attachment hook and the attachment is a little lift-
ed off from the ground.
6. Check that the attachment is horizontal to the left and right
and that each hook is correctly inserted.

7. Operate the lever from “HOLD” position (B) to “TILT” posi-

tion (e), and make the coupler plunger ready to be insert-
ed.
8. Put your hand off the quick coupler attachment switch.
The switch returns to NEUTRAL position (N), the quick
coupler release pilot lamp (1) goes out, and the alarm buz-
zer stops sounding.

9. While pulling the lock (a) of the quick coupler attachment

switch in arrow direction (b), push it down to the coupling
position (C).
Keep the quick coupler attachment switch pressed until the
step 10 is finished.

10. Pull out the coupler plunger and lock the attachment.

g0038100

6-22
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC TYPE QUICK COUPLER

11. Check that the lock pin indicators (3) on left and right side
are visible moved out.
12. Check that the quick coupler and the attachment are com-
pletely locked.
13. Release your hand from the quick coupler attachment
switch.
The switch returns to NEUTRAL position (N).

g0038108

PRECAUTIONS FOR USING HYDRAULIC TYPE QUICK COUPLER

• Check that the lock pin is securely inserted first, then operate the multifunction mono-lever.
• During the removal and installation of the attachment, the
notification of "Hydraulic Pressure Relief Event" may be
displayed on the monitor, however, it is not a problem.

(When the 3-point switch)

• The coupler plunger will be pulled out when the quick cou-
pler attachment switch is returned to NEUTRAL position
(N) from the decoupling position (A).
Before operating the attachment and work equipment,
push down the quick coupler attachment switch to the cou-
pling position (B) first, and check that the coupler plunger
is fully inserted.

6-23
HANDLE FORK ATTACHMENTS AND OPTIONS

HANDLE FORK
EXPLANATION OF COMPONENTS ON MACHINES WITH FORK
(1) Multifunction mono-lever
(2) Attachment selector switch

MULTIFUNCTION MONO-LEVER
The multifunction mono-lever is used to operate the boom and
fork.
NOTICE
Do not use “FLOAT” position when lowering the fork.

6-24
ATTACHMENTS AND OPTIONS HANDLE FORK

Position (a): RAISE

When the multifunction mono-lever is pulled further from the
“RAISE” position, the lever stops in that position.
The boom stops at the preset position and the lever returns to
“HOLD” position at the same time when the remote boom posi-
tioner is enabled.
The boom stops at the highest position and the lever returns to
“HOLD” position at the same time when the remote boom posi-
tioner is disabled.
Position (b): HOLD
The boom and fork remain in the positions where they are stopped.
Position (c): LOWER
Position (d): FLOAT
The boom moves freely under external force.
Position (e): TILT
When the multifunction mono-lever is pulled further from the
“TILT” position, the lever stops in that position. As soon as the
fork reaches the position preset by the fork positioner, the lever
returns to the “HOLD” position.
Position (f): DUMP

ATTACHMENT SELECTOR SWITCH

The attachment selector switch is used to switch the bucket po-
sitioner and fork positioner.
When using the fork, set it to (B) position.
(A) Bucket positioner
Set to this position when using the bucket.
(B) Fork positioner
Set to this position when using the fork.

MACHINE OPERATIONS AND CONTROLS

The operation speed is determined by the terrain, ground condition, load volume, type of load, and how large
the jobsite is.
Keep the engine speed almost maximum during the operation. Use the 1st or 2nd in the speed range for opera-
tion.
Use the 3rd or 4th in the speed range when traveling without load.

6-25
HANDLE FORK ATTACHMENTS AND OPTIONS

METHOD FOR ADJUSTING FORK POSITIONER

1. Lower the fork to the ground, and make it horizontal.

2. Return the multifunction mono-lever to “HOLD” position.

3. Press the work equipment lock switch and lock the work
equipment (the pilot lamp lights up).
4. Stop the engine.

5. If the attachment selector switch is equipped, turn the

switch to fork position (B).

6-26
ATTACHMENTS AND OPTIONS HANDLE FORK

6. Loosen the nut (1). Adjust the position of the proximity

switch (3) so that the rear end (A) of the bar (2) and the
center point of sensory surface (B) of proximity switch (3)
are within the range "a".
a: 37 to 43 mm

7. Adjust the range "c" with nut (1) so that the tip (C) of pro-
tector (5) protrudes 0.5 to 1.0 mm {0.02 to 0.039 in}  from
the sensory surface (B) of all proximity switches (3).
8. Loosen the bolt (4), and adjust the clearance "d" between
the bar (2) and the sensory surface (B) of all proximity
switches (3) so that it is within 3 to 5 mm, and fix it.
Tightening torque: 14.7 to 19.6 Nm {1.5 to 2.0 kgm}

9. After adjustment, run the engine to raise the boom. Check that the lever automatically returns to “HOLD”
position at the point where the fork becomes horizontal, when tilting back the fork after fork DUMP opera-
tion.
REMARK
For more accurate check, keep the HST oil temperature equal to those when the machine is actually oper-
ated.

LOADING AND UNLOADING OPERATION

The following is the explanation how to operate the fork but it does not explain all of the occasions. It may vary
according to the work situation.
Perform the operation of the fork by the most safe and efficient way in each situation.

6-27
HANDLE FORK ATTACHMENTS AND OPTIONS

PICK UP LOAD
k WARNING
• Do not perform rapid turning, rapid acceleration, nor rapid deceleration when carrying the load. Oth-
erwise, the load may fall or the machine may become inclined.
• Tilting angle of the fork varies depending on the load. If the load is stacked higher than the height of
the carriage back, it may slip and fall backward.

1. Adjust the space between the forks according to the size

of the load.
Secure an enough space as possible for the fork so that
the load will be stable.
2. Set the forks horizontal, drive the machine forward slowly,
and insert the forks under the load so that the load can be
loaded on the center of the forks.

3. Keep driving forward until the forks are inserted completely

under the load and the load comes to contact with the car-
riage back.
4. Raise the fork approximately 15 cm off from the ground or
the another one under the load. Tilt the fork so that the
load leans against the carriage back.

5. Check that there is no obstacle rearward. Drive the ma-

chine in reverse so that the load can be lowered.

6. Lower the load to near the ground (approximately 30 cm

off from the ground).

6-28
ATTACHMENTS AND OPTIONS HANDLE FORK

CARRY
k WARNING
• Do not perform rapid turning, rapid acceleration, nor rapid deceleration when carrying the load. Oth-
erwise, the load may fall or the machine may become inclined.
• Tilting angle of the fork varies depending on the load. If the load is stacked higher than the height of
the carriage back, it may slip and fall backward.

• Keep the load at the height near the ground usually when
carrying the load. Perform the steering operation with care
if it is unavoidable to lift the load high.
• Use the 1st or 2nd in the speed range when carrying the
load. Use the 3rd or 4th in the speed range when traveling
without load.
• The appropriate speed for carrying the load varies depend-
ing on the conditions. Think safety first always when driv-
ing the machine. Drive the machine at low speed when
carrying the load on the rough ground or slopes.
• Tilt the load to the mountain side when carrying the load
on the slopes.
• Drive the machine in reverse when the load interrupts the front view.

HOW TO STACK
1. Lift the load to the point approximately 15 cm higher than
the position for the load to be stacked.

2. Drive the machine forward slowly toward the position for

the load to be stacked, and set the fork horizontally.
3. Put down the load.

6-29
HANDLE FORK ATTACHMENTS AND OPTIONS

4. Drive the machine in reverse slowly, and pull the fork off
from the load.
5. Lower the fork.

6-30
ATTACHMENTS AND OPTIONS PCS (PROPORTIONAL CONTROL SWITCH)

PCS (PROPORTIONAL CONTROL SWITCH)

PCS (Proportional Control Switch) is used to operate the third
attachment.
The amount of the hydraulic oil discharged by the switch opera-
tion is in proportion to the stroke of the switch.
The switch has 2 control modes; They are the fixed oil flow
mode and the proportional oil flow mode.
The maximum flow rate at the switching operation and the con-
trol mode can be changed on the machine monitor.
Position (A): RETRACT
Position (B): NEUTRAL
However, this position is for HOLD when switch is operated to limit of position (C) to enable the detent control in
the fixed oil flow mode.
Position (C): EXTEND
Fixed oil flow mode
The maximum flow rate which has been set is held when the
switch is operated to the limit of position (C), and the third at-
tachment continues the operation even if the switch operation
is stopped. This action is called the detent control.
Use this control when the installed attachment requires contin-
uous hydraulic oil flow.
The detent control operation pilot lamp (D) lights up during the
detent control.
The detent control is canceled by any of the following opera-
tions.
• Operate the switch again.
• Turn the work equipment lock switch to ON position.
• Turn the starting switch key to OFF position.
• Stop the engine.
• Cancel the fixed oil flow mode on the machine monitor.
Proportional oil flow mode
This mode does not have the detent control function which the fixed oil flow mode has.
REMARK
The hydraulic oil discharged volume is in proportion to the stroke of the switch in both the fixed oil flow mode
and the proportional oil flow mode.

LCD UNIT
(1) Oil flow control mode pilot lamp (fixed oil flow mode/propor-
tional oil flow mode)
(2) Detent operation pilot lamp
(3) Attachment oil flow level

6-31
PCS (PROPORTIONAL CONTROL SWITCH) ATTACHMENTS AND OPTIONS

OIL FLOW CONTROL MODE PILOT LAMP (FIXED OIL FLOW MODE)
Oil flow control mode pilot lamp (fixed oil flow mode) lights up
when the flow control mode of PCS is in the fixed oil flow
mode.

OIL FLOW CONTROL MODE PILOT LAMP (PROPORTIONAL OIL FLOW MODE)
Oil flow control mode display lamp (proportional oil flow mode)
lights up when the flow control mode of PCS is in the propor-
tional oil flow mode.

DETENT OPERATION PILOT LAMP

The detent operation pilot lamp lights up when the detent con-
trol is performed in the fixed oil flow mode.
(1) to (4) are displayed in order at intervals of 0.5 seconds.

6-32
ATTACHMENTS AND OPTIONS PCS (PROPORTIONAL CONTROL SWITCH)

ATTACHMENT OIL FLOW LEVEL

The attachment oil flow level indicates the maximum flow level
which has been set.
It indicates the level 0 to 8 according to the attachment flow
rate level which has been set. It is displayed in green (A) in the
normal state, and in orange (B) under the detent control.

METHOD FOR SETTING PCS

1. Press the menu switch (1) and enter the setting mode.

2. Select “Attachment Setting” on “Machine Setting and Infor-

mation” menu, and press ENTER switch (2).
If the flow rate mode and the maximum flow rate are set al-
ready, select an arbitrary setting, and the setting is com-
pleted.
If you press the menu switch (1) at this time, you can
change the setting of the selected attachment.
You can save up to 5 settings.

6-33
PCS (PROPORTIONAL CONTROL SWITCH) ATTACHMENTS AND OPTIONS

3. To change the setting name, select “Attachment Name

Setting” and press ENTER switch (2).

Change the alphabet at the cursor with UP or DOWN

switches and move the cursor with menu switch (1).
After completing the change, validate it with ENTER switch
(2).

If you select “Attachment Name Setting” and press the

menu switch (1), you can delete the setting name or return
it to the default value.

4. Select “Flow Control Mode”, and press ENTER switch (2).

You can select “Proportional Control Mode” or “Continuous
Flow Rate Mode”.

5. Select “Attachment Oil Flow Rate Setting”, and press EN-

TER switch (2).
You can set the maximum oil flow at the switch full stroke
and the flow during the detent control in the fixed oil flow
mode.
Change the flow with UP or DOWN switches, and then
press ENTER switch (2).
You can set the maximum flow in the range of 22 to
180 ℓ/min {5.81 to 47.6 US gal/min} at intervals of 22 to
23 ℓ/min {5.81 to 6.08 US gal/min}.

6-34
REPLACEMENT PARTS

7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS REPLACEMENT PARTS

PERIODIC REPLACEMENT OF DEFINED LIFE PARTS

For using the machine safely for an extended period of time, you must periodically replace the safety critical and
fire prevention-related parts listed in the table of the defined life parts.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. Howev-
er, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is
required to replace them with new ones regardless of their condition after a certain period of usage. This is im-
portant to ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the
periodic replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time
as the hoses.
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all
loose hoses and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Have your Komatsu distributor replace the defined life parts.

DEFINED LIFE PARTS LIST

No. Periodical replacement parts Replacement interval
1 Fuel system Fuel hose
Spill hose
2 Steering system High pressure circuit hose
3 Brake system Brake oil pressure hose
4 Torque converter, trans-
HST circuit hose
mission system
5 Work equipment hydraulic Main pump delivery hose
system
Main pump delivery hose other than described
above
Every 2 years or 4000 hours,
Main pump LS hose whichever comes sooner
Hydraulic drive fan hose (Exhaust fan)
External work equipment hose
• Lift cylinder hose
• Bucket cylinder (bottom) hose
• Bucket cylinder (head) hose
• Main valve hose
• Quick coupler hose
6 Others PPC accumulator
Every 3 years from start of us-
age or 5 years after manufac-
Seat belt
turing of seat belt, whichever
comes sooner

7-2
REPLACEMENT PARTS CONSUMABLE PARTS

CONSUMABLE PARTS
Replace consumable parts such as the filter element or air cleaner element at the time of periodic maintenance
or before they reach the wear limit. The consumable parts should be replaced correctly in order to ensure more
economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko-
matsu distributor of the machine serial number and check the latest part number when ordering parts.

CONSUMABLE PARTS LIST

The parts in parentheses are to be replaced at the same time.
Replacement in-
Item Part No. Part Name Q'ty
terval
Engine oil filter 6736-51-5142 Cartridge 1
Every 500 hours
Fuel prefilter 600-319-3610 Cartridge 1
Fuel main filter 600-319-3750 Cartridge 1 Every 1000
HST oil filter 418-18-34160 Cartridge 1 hours

124-15-51740 Strainer 1 -
Transfer strainer Every 1000
(07000-73042) (O-ring) (1)
hours
DEF tank breather 421-60-35170 Element 1
KCCV filter 600-331-2900 Element 1
Hydraulic oil filter 418-60-55150 Cartridge 1
Hydraulic tank breather 285-62-17320 Element 1 Every 2000
hours
Fresh air 423-07-52440 Filter 1
Air conditioner filter Recircula-
423-07-52410 Filter 1
tion air
DEF filter 6540-71-2320 Filter kit 1
419-62-52571 Accumulator 1 Every 4000
PPC accumulator
(07002-12034) (O-ring) (1) hours

421-60-51160 Strainer 1
Hydraulic tank strainer
(07000-15150) (O-ring) (1)
421-43-27920 Strainer 1
Brake circuit strainer (07002-15234) (O-ring) (1)
-
(02896-11015) (O-ring) (1)
Fuel tank breather 421-60-35170 Element 1
Air cleaner 600-185-4100 Element assembly 1
Bolt-on cutting edge See Part No. in Parts Book

7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS

RECOMMENDED FUEL, COOLANT, AND LUBRICANT

NOTICE
• Komatsu genuine oils are conditioned to maintain the reliability and durability of Komatsu construc-
tion equipment and components.
In order to keep your machine in the best condition for long period of time, it is essential to follow
the instructions in this Operation and Maintenance Manual.
• Failure to follow these recommendations may result in shortened life or excessive wear of the en-
gine, power train, cooling system, and/or other components.
• Commercially available lubricant additives may be good or bad for the machine. Komatsu does not
recommend any commercially available lubricant additive.
• Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komat-
su genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect
the engine such as deteriorated oil may reduce lubricating function, and it may cause failure, short-
ening of the machine life, lowering of performance and increase of fuel consumption.
• Use the fuel, the oil and the lubricant according to the ambient temperature as recommended.
• If the machine is operated at a temperature of -20 °C and below, separate devices are needed, so
consult your Komatsu distributor.
NOTICE
The fuel used must be ultra low-sulfur diesel fuel.
(≤10 ppm)
To ensure good fuel consumption characteristics and ex-
haust gas characteristics, the engine mounted on this ma-
chine uses an electronically controlled high-pressure fuel
injection device and emission gas control system (KDPF).
Since the high-pressure fuel injection device requires high
precision parts and lubrication, if low viscosity fuel with
low lubricating ability is used, its durability may drop con-
siderably. And using fuel with high sulfur content can dete-
riorate the engine parts and KDPF catalyzer, inducing fail-
ures, decrease of the life and degradation in performance.
NOTICE
Use DEF as the aqueous urea solution for SCR system.
DEF is a colorless transparent 32.5 % aqueous urea solu-
tion.
The quality of DEF is prescribed in ISO22241-1. Always use
DEF that conforms to this quality standard.

LUBRICATION CHART
• The lubrication chart uses symbols to show the lubrication points and types of lubricant by each lubrication
interval.
• Even if the same symbol is used in the lubrication chart, the recommended genuine oil may differ according
to the lubrication points and the ambient temperature.

7-4
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT

The symbols used in the lubrication chart are explained as follows.

Symbol Meaning of the symbol Symbol Meaning of the symbol
Read the Operation and Maintenance
Lubricating with grease
Manual.

Change the engine oil Check oil level in engine oil pan

Change hydraulic oil Check hydraulic oil level

Change power train oil Change power train oil filter

7-5
RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS

Symbol Meaning of the symbol Symbol Meaning of the symbol

Change engine oil filter Change hydraulic oil filter

Change breather element in hydraulic tank Change fuel filter

Change KCCV filter breather element Change axle oil

Change DEF tank breather element Change DEF filter

METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING

TO AMBIENT TEMPERATURE
Ambient temperature, de-
Recommended grees Celsius ( °C)
Reservoir Fluid type
Komatsu Fluids
Min Max
Engine oil for KDPF used in cold EOS5W30-LA
-25 35
terrain (KES)
(Oil Change interval 250 hours) EOS5W40-LA
-25 40
(Note.1) (KES)
Engine oil pan
EO10W30-LA
-20 40
Engine oil for KDPF (KES)
(Oil Change interval 500 hours) EO15W40-LA
-15 50
(KES)
Transfer case Power train oil TO10 (KES) -30 50
TOS0W30 (KES) -30 50
Power train oil
TOS5W30 (KES) -30 50
Hydraulic System Bio oil BO46-G4 -15 40
EO10W30-DH
Engine oil -20 50
(KES)
Axle oil (Note.2) AXO80 (KES) -30 50
Axle
Power train oil (Note.3) TO50 (KES) 40 50
Pin / Bushing Hyper grease (Note.4) G2-TE (KES) -20 50
Grease fitting Lithium EP grease G2-LI (KES) -10 50
Non-Amine Engine Coolant
Cooling system AF-NAC (KES) -30 50
AF-NAC (Note.5)
EN 590 Class 2 -30 20
Fuel tank Diesel fuel
EN 590 Grade D -10 50
DEF tank DEF (Note.6) DEF -30 50
R134a (HFC
Air conditioner Refrigerant - -
134A)

KES: Komatsu Engineering Standard

7-6
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT

Specified capacity Refill capacity

Reservoir
Liter Liter
Engine oil pan 25.5 23
Transfer case 9.8 5.8
Hydraulic System 146 92
Axle (Front) 27 27
Axle (Rear) 25.5 25.5
Cooling system 35.1 -
Fuel tank 245 -
DEF tank 21.1 -

Air conditioner 1,000 g 1,000 g

REMARK
Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill capacity
means the amount of oil needed to refill the system during inspection and maintenance.
Note 1: KDPF engine oil for cold district is deteriorated easily than that for normal area (replace every 500
hours), so replace oil and filter cartridge every 250 hours. For changing the maintenance time of machine moni-
tor, ask your Komatsu distributor to perform the work.
Note 2: Axle oil AXO80 is capable of preventing the brake and LSD (Limited Slip Differential) from creaking.
When only AXO80 is recommended, use Komatsu genuine AXO80 or equivalent.
Note 3: If the daily operation hours of the machine at ambient temperature above 45 °C exceed 12 hours, TO50
is recommended instead of AXO80.
If TO50 is used, the brake may creak but there is no problem in performance and durability of the brake.
If the machine is equipped with Limited Slip Differential, use AXO80, regardless of the ambient temperature. Do
not use TO50.
Note 4: Hyper grease (G2-TE) has a high performance. When it is necessary to improve the lubricating ability of
the grease in order to prevent squeaking of pins and bushings, the use of G2-TE is recommended.
Note 5: Non-Amine Engine Coolant (AF-NAC)
1. The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of coolant is essential.
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may
cause serious problems in the cooling system, including the engine.
Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant
(AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for
2 years or 4000 hours.
Non-Amine Engine Coolant (AF-NAC) is strongly recommended wherever available.
2. For the density of Non-Amine Engine Coolant (AF-NAC), see “Coolant density table”.
Non-Amine Engine Coolant (AF-NAC) is supplied already diluted. In this case, fill up the tank with pre-dilut-
ed fluid. (Never dilute the Non-Amine Engine Coolant with ordinary water.)

Coolant density table

Min. atmospheric temperature -10 or
-15 -20 -25 -30 -35 -40 -45 -50
( °C) more
Density ( %) 30 36 41 46 50 54 58 61 64
Note 6: The DEF freezes at -11 °C. If thawing is necessary, the DEF system is automatically heated to thaw
DEF after the engine is started.

7-7
RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS

RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU

GENUINE OILS
When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.

7-8
INDEX

INDEX
Symbols Alternator - Check................................................. 4-73
Alternator belt - Check / Replace.......................... 4-63
12/24 display mode...............................................3-84 Always use clean washer fluid................................ 4-2
2-stage low idle switch........................................ 3-100 Appoint leader when working with others............. 2-33
2-stage low idling pilot lamp..................................3-32 Armrest adjustment knob........................................ 6-6
Armrest angle - Adjust........................................ 3-166
A Armrest height and angle - Adjust.......................3-173
Armrest right-left adjustment bolt............................ 6-7
Abnormal points detected up to previous day - Check. Ashtray................................................................ 3-115
.....................................................................3-181 Attachment - Install....................................... 6-18,6-20
Accelerator pedal................................................ 3-110 Attachment - Remove................................... 6-15,6-17
Acronyms.............................................................. 1-16 Attachment oil flow level....................................... 6-33
Action level display............................................... 3-16 Attachment selector switch......................... 3-105,6-25
Actions if engine stops........................................ 3-196 Auto idle stop timer setting....................................3-70
Actions if fire occurs..............................................2-17 Auto switch..........................................................3-217
Actions when running out of fuel.........................3-233 Auto-greasing......................................................3-122
After cold weather season.................................. 3-230 Auto-greasing - Check / Fill grease.......................4-44
After finishing work - Check................................ 3-208 Automatic fan-reverse operation...........................4-31
Aftertreatment devices - Disable while regeneration is Automatic warm-up system - Operate................ 3-180
performed.................................................... 3-133 Average fuel consumption display - Set................3-54
Aftertreatment devices - Set regeneration disable Average fuel consumption record......................... 3-52
while regeneration is not performed............ 3-132 Avoid mixing oil....................................................... 4-3
Aftertreatment devices regeneration.....................3-72 Axle breather - Clean............................................ 4-29
Aftertreatment devices regeneration disable - Cancel. Axle case - Change oil.......................................... 4-69
.....................................................................3-134 Axle case - Check oil level / Add oil...................... 4-28
Aftertreatment devices regeneration disable - Set....... Axle serial plate location....................................... 1-11
.....................................................................3-132
Aftertreatment devices regeneration pilot lamp.... 3-34
Air cleaner - Check............................................... 4-16
B
Air cleaner - Check / Clean / Replace...................4-15 Backup alarm...................................................... 3-121
Air cleaner clogging caution lamp......................... 3-28 Battery.................................................................3-229
Air cleaner element - Replace...............................4-19 Battery - Check electrolyte level from side............4-48
Air cleaner outer element - Clean......................... 4-17 Battery - Check electrolyte level impossible from side.
Air conditioner - Check / Maintain......................... 4-37 .......................................................................4-48
Air conditioner - Handle...................................... 3-213 Battery - Handle.................................................... 2-37
Air conditioner - Operate.....................................3-219 Battery disconnect switch....................................3-119
Air conditioner - Start automatic operation..........3-219 Battery electrolyte level - Check........................... 4-47
Air conditioner - Stop automatic operation..........3-220 Beacon lamp switch.............................................. 3-97
Air conditioner - Stop manual operation..............3-221 Beware of asbestos dust.......................................2-24
Air conditioner compressor - Check / Adjust.........4-82 Bolt-on cutting edge - Invert / Replace..................4-33
Air conditioner compressor belt - Adjust............... 4-51 Boom - Operate.................................................. 3-194
Air conditioner compressor belt - Check............... 4-50 Boom raise detent setting..................................... 3-67
Air conditioner compressor belt - Check for replace- Brake - Use........................................................... 2-28
ment time....................................................... 4-50 Brake accumulator - Check function.............4-40,4-52
Air conditioner compressor belt tension - Check / Ad- Brake circuit strainer - Clean.................................4-71
just................................................................. 4-49 Brake disc - Check wear....................................... 4-72
Air conditioner condenser - Clean.........................4-30 Brake oil pressure caution lamp............................3-20
Air conditioner display...........................................3-33 Brake oil temperature caution lamp...................... 3-21
Air conditioner fresh air filter - Clean.....................4-47 Brake pedal.........................................................3-109
Air conditioner recirculation air filter - Clean......... 4-52 Brake pedal - Check........................................... 3-181
Air conditioner recirculation air filter and fresh air filter Bucket - Check angle..........................................3-205
- Replace....................................................... 4-70 Bucket - Operate.................................................3-195
Air conditioner switch.......................................... 3-218 Bucket and tire selection.........................................6-2
Air conditioner switch and numeric keypad...........3-46 Bucket positioner - Adjust................................... 3-203
Air conditioner system caution lamp..................... 3-28 Bucket teeth - Replace..........................................4-34
Alternate exit of cab - Check...............................3-163

8-1
 INDEX

C DEF hose - Replace..............................................4-84

DEF level - Check............................................... 3-196
Cab door - Open / Close..................................... 3-110 DEF level caution lamp......................................... 3-22
Cab door handle.................................................. 3-111 DEF level gauge................................................... 3-43
Calendar setting....................................................3-81 DEF low level guidance........................................ 3-37
Cap and cover with lock...................................... 3-114 DEF system caution lamp..................................... 3-25
Carry..................................................................... 6-29 DEF system high-temperature stop caution lamp.3-25
Centralized warning lamp..................................... 3-29 DEF tank - Clean.................................................. 4-83
Charge level caution lamp.................................... 3-27 DEF tank breather element - Replace.................. 4-79
Chassis - Phenomena and actions..................... 3-241 Defined life parts list....................................... 4-81,7-2
Check drained oil and used filter.............................4-2 Defroster - Operate............................................. 3-222
Check service meter reading.................................. 4-2 Defroster function - Check.................................. 3-163
Check signs and signalman's signals................... 2-23 Defroster switch.................................................. 3-219
Checks after inspection and maintenance.............. 4-3 Demist - Operate.................................................3-222
Checks after stopping engine............................. 3-208 Detent operation pilot lamp................................... 6-32
Checks and adjustment before starting engine............ Dig and load on horizontal surface..................... 3-197
.............................................................2-24,3-151 Digging work....................................................... 3-196
Checks before operation.......................................2-26 Dimmer switch...................................................... 3-94
Checks before starting.......................................... 4-44 Directional lever.................................................. 3-108
Checks before stopping engine.......................... 3-208 Directional selector pilot lamp............................... 3-32
Chemical hazard................................................... 2-40 Directional selector switch.................................... 3-99
Cigarette lighter.....................................................3-94 Directional selector switch actuation switch........3-105
Clearance between brake pedal and floor - Check...... Directional switch caution lamp.............................3-22
.....................................................................3-181 Directions of machine............................................. 1-8
Clearance lamp pilot lamp.................................... 3-32 Display monitor................................................... 3-218
Clock..................................................................... 3-34 Display warning tag during inspection and mainte-
Clock - Adjust........................................................3-80 nance............................................................. 2-33
Cold weather operation.......................................3-229 Display/non-display of ECO gauge - Switch......... 3-55
Cold weather operation information.................... 3-229 Display/non-display of ECO guidance - Switch.....3-57
Configurations.......................................................3-54 Display/non-display of guidance when key is OFF -
Consumable parts...................................................7-3 Switch............................................................ 3-58
Consumable parts list............................................. 7-3 Do not drop things inside machine..........................4-2
Contents of safety labels.........................................2-7 Do not get caught..................................................2-20
Control levers and pedals................................... 3-107 Do not go close to high-voltage cables................. 2-22
Control panel position adjuster lever.......................6-7 Down switch..........................................................3-46
Controls and gauges names................................... 3-3 Dozing work........................................................ 3-199
Cool box.............................................................. 3-114 Drive shaft - Lubricate...........................................4-81
Coolant................................................................3-229 Dust indicator - Check.........................................3-157
Coolant - Check level / Add................................ 3-156 Dusty jobsite........................................................... 4-3
Coolant and water for dilution................................. 4-6
Cooling system - Clean inside.............................. 4-21 E
Cover with lock - Lock.........................................3-210
Cover with lock - Open........................................3-210 ECO gauge........................................................... 3-41
Cover with lock - Open / Close........................... 3-210 ECO guidance.......................................................3-36
Cross drive loading............................................. 3-200 ECO guidance record........................................... 3-51
Cup holder...........................................................3-114 Eco traveling mode............................................... 3-65
Current abnormality screen...................................3-17 ECSS accumulator - Check function.....................4-40
ECSS pilot lamp....................................................3-32
D ECSS switch......................................................... 3-98
Electric wiring - Check........................................ 3-158
Damper gear - Check wear amount......................4-83 Electrical components - Handle.............................. 4-9
Daylight saving time..............................................3-84 Electrolyte level - Check when it is possible to use in-
Declaration of conformity...................................... 1-14 dicator............................................................ 4-49
DEF...............................................................3-229,4-6 Emergency exit from operator's cab..................... 2-20
DEF - Check level / Add......................................3-159 Emergency HST pump drive pilot lamp................ 3-35
DEF - Store............................................................. 4-8 Emergency HST pump drive switch....................3-101
DEF filter............................................................. 3-150 End of service life......................................... 2-34,4-84
DEF filter - Replace...............................................4-77 Energy saving guidance........................................3-49

8-2
INDEX

Engine - Check low-speed run and acceleration 3-180 Fan control system caution lamp.......................... 3-28
Engine - Check starting condition and unusual noise.. Fan reverse rotation display..................................3-33
.....................................................................3-180 Fan switch...........................................................3-214
Engine - Operate / Check after starting.............. 3-180 Filter........................................................................ 4-8
Engine - Operate / Check before starting........... 3-174 Fin - Clean by rotating cooling fan in reverse....... 4-31
Engine - Start............................................3-176,3-240 Fin - Clean with compressed air........................... 4-31
Engine - Start in cold weather.............................3-178 Fins - Open engine side cover / Clean..................4-33
Engine - Start in normal weather........................ 3-176 Fins - Open rear grille / Clean...............................4-32
Engine - Start with jumper cables....................... 3-239 Fluorinated greenhouse gases............................. 1-12
Engine - Stop...................................................... 3-183 Fork - Handle........................................................ 6-24
Engine coolant temperature caution lamp............ 3-19 Fork positioner - Adjust......................................... 6-26
Engine coolant temperature gauge.......................3-40 Forking work....................................................... 3-200
Engine damper breather - Clean...........................4-27 Frame lock bar.................................................... 3-118
Engine high-pressure piping clamp - Check for loose- Fresh and clean lubricants......................................4-2
ness and hardening of rubber........................4-82 Freshrecirc air selector switch............................ 3-217
Engine intake pipe clamps - Check all tightening Front wiper - Handle........................................... 3-122
points............................................................. 4-63 Front wiper switch................................................. 3-96
Engine oil level caution lamp................................ 3-26 Front working lamp switch.................................... 3-99
Engine oil pan - Change oil / Engine oil filter cartridge Fuel......................................................................... 4-5
- Replace....................................................... 4-53 Fuel - Check level / Add......................................3-158
Engine oil pan - Check oil level / Add oil.............3-156 Fuel and lubricants..............................................3-229
Engine oil pressure caution lamp..........................3-26 Fuel and lubricants to match ambient temperature.4-4
Engine overrun caution lamp................................ 3-27 Fuel circuit - Bleed air......................................... 3-233
Engine shutdown secondary switch....................3-106 Fuel filler port cap - Lock.....................................3-209
Engine side cover - Close securely.........................4-4 Fuel filler port cap - Open................................... 3-209
Engine stop operation during the aftertreatment devi- Fuel gauge............................................................ 3-40
ces regeneration guidance............................ 3-38 Fuel level caution lamp......................................... 3-20
Engine system caution lamp................................. 3-25 Fuel main filter cartridge - Replace....................... 4-57
Engine tachometer................................................3-39 Fuel prefilter cartridge - Replace...........................4-55
Engine technology to conform exhaust gas emission . Fuel spray prevention cap - Check for missing and
.........................................................................1-9 hardening of rubber....................................... 4-83
Engine valve clearance - Check / Adjust.............. 4-74 Fuel spray prevention cap - Replace.................... 4-83
Ensure good visibility............................................ 2-23 Fuel tank - Drain water and sediment................... 4-46
Ensuring safe operation........................................ 2-15 Fuel tank - Open / Close fuel filler port cap.........3-209
Enter switch.......................................................... 3-45 Fuel tank breather element - Clean / Replace...... 4-42
EU DIRECTIVES.................................................... 1-2 Fuel, coolant and lubricants according to ambient
Every 100 hours maintenance.............................. 4-46 temperature - Use............................................7-6
Every 1000 hours maintenance............................ 4-57 Fuse.................................................................... 3-115
Every 2000 hours maintenance............................ 4-63
Every 250 hours maintenance.............................. 4-47 G
Every 4000 hours maintenance............................ 4-80
Every 4500 hours maintenance............................ 4-83 General character and precautions for handling...2-43
Every 50 hours maintenance................................ 4-46 General precautions common to operation and main-
Every 500 hours maintenance.............................. 4-53 tenance.......................................................... 2-15
Every 8000 hours maintenance............................ 4-83 General view........................................................... 3-2
Every 9000 hours maintenance............................ 4-84 GPS synchronization............................................ 3-80
Excessive idling guidance.....................................3-37 Grease.................................................................... 4-7
Explanation of air conditioner equipment............3-214 Guards.................................................................. 2-34
Explanation of components...................................3-10 Guidance of accelerator pedal depressing limit.... 3-37
Explanation of components on machine with fork.6-24 Guidance to avoid hydraulic relief.........................3-37
Explanation of components on machine with quick
coupler........................................................... 6-14 H
Explanation of joystick steering system.................. 6-3
Explanation of machine monitor equipment..........3-10 Handle oil, fuel, coolant, and performing oil clinic...4-5
Hazard lamp switch...............................................3-99
Headlamp (high beam) pilot lamp......................... 3-31
F Headrest - Adjust angle...................................... 3-165
Fan - Operate in reverse manually....................... 4-31 Headrest - Adjust in vertical direction................. 3-166

8-3
 INDEX

Headrest - Install.................................................3-168 KDPF system caution lamp...................................3-24

Headrest - Remove.............................................3-168 Keep machine clean............................................. 2-15
Headrest - Remove / Install................................ 3-168 KMAX tooth - Replace.......................................... 4-35
High-pressure hoses and pipings - Handle...........2-39 Komatsu Closed Crankcase Ventilation (KCCV) 3-134
Horn - Check.......................................................3-163 Komatsu Diesel Particulate Filter (KDPF) - Handle.....
Horn switch..................................................... 3-95,6-5 .....................................................................3-126
How to stack......................................................... 6-29 Komatsu genuine lubricants....................................4-2
HST oil filter cartridge - Replace........................... 4-61 Komatsu genuine replacement parts...................... 4-2
HST oil filter clogging caution lamp.......................3-23 KOMTRAX.......................................................... 3-150
HST oil temperature caution lamp........................ 3-20
HST oil temperature gauge...................................3-40 L
HST system caution lamp..................................... 3-23
Hydraulic circuit - Bleed air..................................... 4-3 L.H. and R.H. meters............................................ 3-41
Hydraulic oil filler port cap - Lock........................ 3-210 L.H. meter display - Select....................................3-77
Hydraulic oil filler port cap - Open.......................3-209 Lamp switch.......................................................... 3-94
Hydraulic oil filter cartridge - Replace................... 4-66 Language settings.................................................3-85
Hydraulic tank - Change oil / Clean strainer......... 4-63 LCD unit................................................................ 6-31
Hydraulic tank - Check oil level / Add oil...............4-46 Leveling work...................................................... 3-198
Hydraulic tank breather element - Replace...........4-68 Lever stand - Adjust............................................ 3-173
Hydraulic tank oil filler cap - Open / Close.......... 3-209 Lifting of personnel prohibited...............................2-19
Hydraulic type quick coupler - Handle.................. 6-14 Load-and-carry operation....................................3-199
Loading and unloading operation..........................6-27
Loading work.......................................................3-199
I Location of engine number plate...........................1-10
If any problem is found..........................................2-16 Location of product identification number (PIN)/ ma-
If brake does not stop machine...........................3-195 chine serial number plate...............................1-10
If machine monitor shows warning display......... 3-245 Location of safety labels......................................... 2-5
Initial 10 hours maintenance (only for the first 100 Lock.................................................................... 3-208
hours).............................................................4-15 Lock inspection cover............................................. 4-3
Initial 250 hours maintenance (only 1st maintenance Locks - Check..................................................... 3-163
of new machine)............................................ 4-15 Low fuel consumption operation......................... 3-200
Inside operator's compartment............................. 2-16 Lower center of gravity during turning.................3-195
Inspecting machine............................................... 2-15 Lubrication chart..................................................... 7-4
Introduction............................................................. 1-8 Lumbar support - Adjust......................................3-166
Investigate and confirm jobsite conditions............ 2-22
M
J Machine - Check walk-around............................ 3-151
Joystick activation switch........................................ 6-4 Machine - Get on or off..........................................6-11
Joystick console - Adjust.......................................6-12 Machine - Lift...................................................... 3-227
Joystick console fore-aft adjustment knob.............. 6-6 Machine - Load................................................... 3-223
Joystick console lift up............................................ 6-5 Machine - Load / Unload with trailer................... 3-223
Joystick directional selector switch......................... 6-4 Machine - Operate after starting engine............. 3-181
Joystick ON/OFF switch..........................................6-4 Machine - Operate in emergency........................3-237
Joystick pilot lamp...................................................6-7 Machine - Park....................................................3-206
Joystick steering lever.............................................6-5 Machine - Running-in the new machine..............3-181
Joystick steering lever operation and steering wheel Machine - Secure................................................3-223
operation - Select........................................... 6-11 Machine - Start....................................................3-184
Joystick steering system - Function / Structure...... 6-8 Machine - Start (Travel forward and reverse, and shift
Joystick steering system - Handle.......................... 6-3 gear) / Stop.................................................. 3-184
Joystick steering system - Operate.........................6-9 Machine - Start after long-term storage.............. 3-231
Jumper cable - Connect......................................3-239 Machine - Steer...................................................3-192
Jumper cable - Disconnect................................. 3-240 Machine - Stop....................................................3-191
Machine - Switch travel direction........................ 3-188
K Machine - Transport............................................ 3-223
Machine - Unload................................................3-226
KCCV filter element - Replace.............................. 4-74 Machine equipment name.......................................3-2
KDPF - Clean........................................................4-83 Machine monitor - Check.................................... 3-162
KDPF soot accumulation caution lamp................. 3-24

8-4
INDEX

Machine monitor - Display when starting engine while Oil............................................................................4-5

engine shutdown secondary switch is ON..... 3-12 Oil flow control mode display lamp (proportional oil
Machine monitor - Operate................................... 3-11 flow mode)..................................................... 6-32
Machine monitor - Operate when operator identifica- Oil flow control mode pilot lamp (fixed oil flow mode)..
tion function is available with skip..................3-86 .......................................................................6-32
Machine monitor - Operate when operator identifica- Only authorized personnel.................................... 2-33
tion function is available without skip.............3-88 Open handle for cab L.H. door............................ 3-111
Machine monitor - Operate when starting engine in Open knob for alternate exit of cab..................... 3-112
abnormal situation......................................... 3-14 Open lock for cab L.H. door.................................3-111
Machine monitor - Operate when starting engine in Operating records................................................. 3-49
normal situation..............................................3-11 Operator ID........................................................... 3-86
Machine monitor - Operate when starting switch is Operator's seat - Adjust...................................... 3-163
ON while operator ID input is set................... 3-13 Other components...............................................3-110
Machine monitor - Operate when stopping engine in Other equipment name........................................... 3-7
normal situation............................................. 3-12 Other functions of machine monitor...................... 3-91
Machine monitor - Operate when trouble occurs while Other precautions................................................. 2-43
operating machine......................................... 3-15 Other trouble....................................................... 3-240
Machine monitor equipment name..........................3-5 Outline of maintenance........................................... 4-5
Machine operations and controls................3-151,6-25
Machine setting and information........................... 3-59 P
Main use of machine...............................................1-8
Maintenance and schedule of air conditioner....... 4-39 Parking brake - Check................................ 3-181,4-49
Maintenance during long-term storage............... 3-231 Parking brake - Release..................................... 3-236
Maintenance interval when diesel fuel mixed with bio- Parking brake pilot lamp....................................... 3-36
fuel is used.....................................................4-13 Parking brake switch.............................................3-96
Maintenance of air conditioner..............................2-40 PCS - Set.............................................................. 6-33
Maintenance procedure........................................ 4-15 PCS (Proportional Control Switch)............. 3-102,6-31
Maintenance schedule.......................................... 4-12 Perform KOWA (Komatsu Oil Wear Analysis)........ 4-7
Maintenance schedule table................................. 4-12 Periodic replacement of defined life parts.............2-41
Maintenance screen - Set..................................... 3-72 Permissible water depth......................................3-195
Maintenance time caution lamp............................ 3-28 Phenomena and actions for electrical system.... 3-240
Manual operation................................................ 3-220 Phenomena and actions for engine related parts........
Manual stationary regeneration - Operate.......... 3-130 .....................................................................3-243
Max. traction switch............................................ 3-102 Pick up load.......................................................... 6-28
Menu switch.......................................................... 3-45 Pilot display...........................................................3-30
Message - Check.................................................. 3-90 Power supply for KOMTRAX.............................. 3-150
Message - Reply................................................... 3-90 Power supply outlet.............................................3-115
Message display........................................... 3-34,3-89 PPC accumulator - Check function....................... 4-73
Meter display.........................................................3-39 Precautions about load-and-carry operation.......3-212
Meter display selection......................................... 3-77 Precautions after daily work completion in cold
Method for adjusting........................................... 3-163 weather........................................................ 3-230
Method for checking before starting....................3-153 Precautions before starting inspection and mainte-
Mirrors - Adjust....................................................3-168 nance............................................................. 2-33
Monitor brightness selector switch........................3-95 Precautions before starting operation................... 2-15
Monitor settings.....................................................3-75 Precautions for adding.......................................... 2-43
Monitor switches................................................... 3-43 Precautions for adding DEF....................................4-2
Monobloc type teeth - Replace............................. 4-34 Precautions for charging battery......................... 3-238
Multifunction mono-lever.............................3-108,6-24 Precautions for check and maintenance...............2-37
Precautions for cleaning cab glass....................... 2-20
Precautions for cold weather................................ 2-25
N Precautions for compressed air............................ 2-40
No jumping on or off machine............................... 2-19 Precautions for DEF..............................................2-43
No people on attachments.................................... 2-19 Precautions for discharged battery..................... 3-237
Noise emission levels............................................. 1-6 Precautions for disposing of waste materials........2-40
Precautions for fire hazard and leakage............... 2-43
O Precautions for getting on or off machine............. 2-18
Precautions for handling tires..............................3-211
OFF switch..........................................................3-214 Precautions for high-pressure fuel........................ 2-39

8-5
 INDEX

Precautions for high-pressure oil.......................... 2-39 Q

Precautions for high-temperature coolant.............2-38
Precautions for high-temperature oil.....................2-39 Quick coupler attachment switch.......................... 6-14
Precautions for high-temperature parts................ 2-39 Quick coupler lock release pilot lamp................... 6-15
Precautions for installing, removing, or storing attach-
ments............................................................. 2-36 R
Precautions for jobsite.......................................... 2-22
Precautions for KDPF............................................. 4-2 R.H. meter display - Select................................... 3-78
Precautions for long-term storage.......................3-231 Radiator coolant level caution lamp...................... 3-27
Precautions for maintenance.......................... 2-33,4-2 Radiator fan automatic reverse mode...................3-61
Precautions for noise............................................ 2-40 Radiator fan manual reverse mode.......................3-59
Precautions for operation................... 2-22,2-26,3-195 Radiator fin and cooler fin - Clean........................ 4-31
Precautions for refilling oil or fuel............................4-2 Raise remote boom positioner - Operate............3-201
Precautions for removing and installing battery.. 3-238 Raise remote boom positioner - Release............3-202
Precautions for SCR assembly............................... 4-3 Read this manual.................................................... 1-2
Precautions for storing.......................................... 2-43 Rear heated wire glass switch............................ 3-100
Precautions for storing tires.................................. 2-42 Rear view camera guide line - Check................. 3-172
Precautions for towing and being towed............... 2-32 Rear view monitor brightness adjustment switch..3-95
Precautions for towing machine..........................3-234 Rear wiper switch..................................................3-97
Precautions for transportation...............................2-31 Rear working lamp switch..................................... 3-97
Precautions for traveling on slopes.......................2-28 Rearview camera - Adjust...................................3-169
Precautions for using hydraulic type quick coupler...... Rearview camera angle - Adjust......................... 3-169
.......................................................................6-23 Rearview monitor - Handle................................. 3-125
Precautions for welding.........................................2-37 Rearview monitor - Set......................................... 3-75
Precautions for working at high places................. 2-36 Recommended applications................................3-196
Precautions for working under machine or work Recommended brands and qualities other than ko-
equipment...................................................... 2-36 matsu genuine oils...........................................7-8
Precautions in cold weather................................3-230 Recommended fuel, coolant, and lubricant.............7-4
Precautions related to attachments and options...2-21 Refrigerant (gas) level - Check............................. 4-37
Precautions related to protective structure........... 2-20 Remaining time for maintenance - Reset..............3-73
Precautions to prevent fire.................................... 2-17 Remote positioner...............................................3-201
Precautions when installing hydraulic hoses.......... 4-3 Remote positioner pilot lamp................................ 3-33
Precautions when leaving machine...................... 2-19 Remote positioner switch......................................3-99
Precautions when loading and unloading............. 2-31 Replace defined life parts..................................... 4-80
Precautions when operating joystick steering system.. Retrofitting by third-party suppliers....................... 1-15
.........................................................................6-8 Return switch........................................................ 3-45
Precautions when operating machine...................2-29 Reverse travel speed range limitation...................3-66
Precautions when operating on snow or frozen surfa- Reverse-interlock selection mode.........................3-76
ces................................................................. 2-30 Room lamp switch.................................................3-97
Precautions when parking machine...................... 2-30 ROPS/FOPS serial plate location......................... 1-11
Precautions when running engine inside building.2-21
Precautions when standing up from operator's seat.... S
.......................................................................2-19
Safety......................................................................2-2
Precautions when starting engine.........................2-25
Safety information................................................... 1-4
Precautions when traveling.........................2-27,3-196
Safety labels..................................................... 1-5,2-4
Precautions when traveling in forward or reverse.2-26
Safety-related equipment......................................2-15
Precautions when traveling on slopes................ 3-195
SCR information....................................................3-72
Precautions when using hammer..........................2-38
Screen adjustment................................................ 3-79
Precautions when working on loose ground......... 2-22
Seat - Heat..........................................................3-167
Preheating pilot lamp............................................ 3-33
Seat - Recline..................................................... 3-164
Preparation for long-term storage....................... 3-231
Seat belt - Fasten................................................3-173
Preparations for safe operation.............................2-15
Seat belt - Fasten / Unfasten.............................. 3-172
Prevent fire............................................................2-17
Seat belt - Unfasten............................................ 3-173
Product information...............................................1-10
Seat belt caution lamp.......................................... 3-22
Prohibited operations............................................ 2-29
Seat cushion - Adjust in fore-after direction........ 3-165
Provide fire extinguisher and first aid kit............... 2-16
Seat plate location................................................ 1-12
PZ auto tilt-in.......................................................3-205
Seat tilt - Adjust...................................................3-164
PZ auto tilt-in select.............................................. 3-68
Seat unit - Adjust fore-and-aft direction.............. 3-164

8-6
INDEX

Secondary steering pilot lamp...............................3-35 Transfer case - Check oil level / Add oil................4-25
Secondary steering system - Handle.................. 3-193 Transfer case breather - Clean............................. 4-59
Select suitable place for inspection and maintenance. Transmission serial plate location......................... 1-11
.......................................................................2-33 Transportation..................................................... 3-223
Service meter location.......................................... 1-12 Travel downhill.................................................... 3-195
Shift position display............................................. 3-36 Travel speed control dial....................................... 3-95
Slow-blow fuse.................................................... 3-117 Trip meter..............................................................3-70
Slow-blow fuse - Replace..................................... 4-39 Troubles and actions...........................................3-233
Specifications..........................................................5-2 Turbocharger protection function........................ 3-179
Specifications - WA320-8........................................5-2 Turn battery disconnect switch to off position....... 2-37
Speed range - Select.......................................... 3-187 Turn off ecss switch before performing inspection and
Speed range selector switch...............................3-106 maintenance.................................................. 2-36
Speedometer........................................................ 3-39 Turn signal lever....................................................3-94
Stability................................................................. 2-33 Turn signal pilot lamp............................................ 3-31
Standard tightening torque for bolts and nuts....... 4-10 Two workers for maintenance when engine is running
Start engine...........................................................2-24 .......................................................................2-35
Start engine with jumper cables............................2-25
Starting motor - Check.......................................... 4-82 U
Starting motor - Replace....................................... 4-83
Starting switch.......................................................3-93 Unauthorized modification.................................... 2-21
Steering low oil pressure caution lamp................. 3-35 Understanding the machine.................................. 2-15
Steering oil pressure caution lamp........................3-23 Unlock knob for slide window of cab................... 3-112
Steering tilt lock lever..........................................3-109 Up switch.............................................................. 3-45
Stockpile - Load.................................................. 3-197 Urea SCR system warning - Handle................... 3-135
Stop engine before carrying out inspection and main- Use handrails and steps when getting on or off ma-
tenance.......................................................... 2-34 chine.............................................................. 2-18
Store oil and fuel..................................................... 4-8 Use proper tools....................................................2-37
Sunlight sensor................................................... 3-219 Use warning tags.................................................. 2-24
Suspension damper hardness - Adjust............... 3-166 User menu............................................................ 3-46
Switch panel equipment name................................3-4
Switches................................................................3-92 V
System caution lamp.............................................3-21
System operating lamp....................................... 3-121 V-shape loading.................................................. 3-200
Variable speed display.......................................... 3-41
Vent selector switch - Select............................... 3-216
T Vibration damper - Check..................................... 4-74
Target fuel consumption value displayed in ECO Vibration level......................................................... 1-7
gauge - Set.................................................... 3-56 Visibility from operator's seat.................................. 1-8
Temperature control switch................................. 3-215
Time - Set..............................................................3-83 W
Tip type teeth - Replace........................................ 4-34
Tire - Handle............................................... 2-41,3-211 Warning display............................................ 3-15,3-23
Tire - Select / Check..............................................4-41 Water pump - Check............................................. 4-82
Tire inflation pressure - Check............................ 3-162 Water separator - Check / Drain water and sediment..
Tire inflation pressure - Check and inflate.............4-42 .....................................................................3-154
Tire pressure....................................................... 3-211 Water separator caution lamp............................... 3-27
Tires...................................................................... 2-41 Wear well-fitting clothes and protective equipment......
Tires - Select......................................................... 4-41 .......................................................................2-15
Towing and being towed....................................... 2-32 Weight and height of seat - Adjust...................... 3-164
Towing pin - Use..................................................3-118 Welding instructions................................................4-2
Towing when engine can run.............................. 3-235 Wheel hub bolts - Check looseness / Retighten... 4-51
Towing when engine does not run...................... 3-236 When handling accumulator and gas spring.........2-40
Traction control recommendation guidance.......... 3-37 When it is impossible to travel while engine is running
Traction control switch........................................ 3-102 .....................................................................3-235
Traction level display.............................................3-35 When required...................................................... 4-15
Traction level selection..........................................3-63 Window washer fluid - Check level / Add..............4-37
Traction level selection hold..................................3-64 Window washer fluid - select................................ 2-41
Transfer case - Change oil / Clean strainer.......... 4-59 Window washer fluid spouting out - Check......... 3-162
Wiper function - Check........................................3-162

8-7
 INDEX

Wiper switch............................................................6-5
Work equipment - Adjust posture........................3-201
Work equipment - Operate..................................3-194
Work equipment lock pilot lamp............................ 3-36
Work equipment lock switch............................... 3-100
Work equipment system caution lamp.................. 3-21
Work place - Clean / Tidy......................................2-33

Y
Your machine serial numbers and distributor........1-12

8-8