Wa320-5 M 50051up 0311 PDF

VEAM240100
Operation & Maintenance

Manual
WHEEL LOADER
-5H
SERIAL NUMBERS WA320H50051 AND UP
DANGER
Incorrect operation and maintenance of this machine
may be hazardous and cause injuries. The operator and
maintenance personnel must read this manual before
commencing operation or maintenance. Keep this
manual within reach at all times and ensure that
operating personnel read it at regular intervals.
NOTE
Komatsu has had the operating and maintenance instructions
translated into all the languages of the European Union.
Should you require a copy in another language please inquire
at your local dealer’s.
FOREWORD
11
FOREWORD FOREWORD
FOREWORD 1
This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre-
cautions in this manual must be followed at all times when performing operation and maintenance. Most accidents
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci-
dents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation
and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.
Always be sure to read and understand this manual thoroughly before performing operation and mainte-
nance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly
and be sure that you understand them fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have
all personnel read it periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual imme-
diately from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating
the machine.
Storage location for the Operation and Maintenance Manual:

Pocket (1) at rear of operator's seat
1-2
FOREWORD FOREWORD
EU DIRECTIVES 0.
Machines supplied by us fulfil the Directive for Machinery 89/392/EEC and all supplements. If the machine is being
used in another country, it is possible that certain safety regulations and specifications may not be fulfilled for use
in that country. For example, priority vehicle warning lamps may be used in some countries, but are forbidden in
others.
Please contact our dealer before using the machine if you have any questions regarding the fulfilment of standards
and regulations in a specific country.
Notes on subsequent installation of electrical and electronic equipment and components

Electrical and electronic equipment and/or components which have been installed subsequently, emit electromag-
netic radiation which can influence the function of the electronic components and sections of the machine. This
can have an influence on the safety of the machine and endanger persons. For this reason, please ensure that the
following safety instructions are observed.
If you are installing electrical or electronic equipment and/or components in the machine and connect them to the
vehicle electrical system, you must check at own responsibility that the installations do not cause any disturbance
to the vehicle’s electronic system or other components. Above all, you must ensure that any subsequently installed
electrical and electronic components comply with the EMV Directive 89/336/EEC in its current edition and bear the
CE mark.
The following requirements also have to be met for subsequent installation of mobile communication systems (e.g.
q Only equipment approved by national legislation (e.g. BZT approval for Germany) may be used
radio, telephone):
q The unit must be fixed in position
q Portable or mobile units may only be used inside the vehicles if they are connected to a fixed outside
antenna
q The transmitter unit must be spatially separated from the vehicle’s electronic system
q 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 permitted
power consumption.
1-3
SAFETY INFORMATION FOREWORD
SAFETY INFORMATION 1
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
erate injury. This word is used also to alert against unsafe practices that may cause prop-
erty damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or
death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
1-4
FOREWORD SAFETY INFORMATION
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
For details of safety labels, see "SAFETY LABELS (2-3)".
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-

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

prepared based on the latest information available at that time.
Continuing improvements in the design of this machine can
lead to changes in detail which may not be reflected in this
manual. Consult Komatsu or your Komatsu distributor for the
latest available information of your machine or for questions
regarding information in this manual.
The numbers in circles in the illustrations correspond to the

numbers in ( ) in the text. (For example: 1 -> (1))
1-5
INTRODUCTION FOREWORD
INTRODUCTION 1
This loader is a machine with independent transmission, moving on chains or wheels. Driving in forward direction,
the loader can load or dig material using its attachments intended for loading operations (i.e. bucket).
The standard operation cycle of a loader includes filling up and loading of the bucket, transporting the material and
emptying the bucket.
INTENDED USE
If you use the machine for any other purpose than specified above, we will not accept any responsibility for safety.
All considerations concerning safety will then be up to the owner or the operating and maintenance personnel. In
any case, neither you nor any other person are/is authorised to perform work and functions explicitly prohibited in
these operating instructions.
The transport of persons in the work equipment is strictly forbidden!
For details of the operating procedure, see “WORK POSSIBLE USING WHEEL LOADER (3-86)“.
DIRECTIONS OF MACHINE 1
Front
Bucket
Left Right
Rear
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
1-6
FOREWORD NECESSARY INFORMATION
NECESSARY INFORMATION 1
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NO. PLATE AND POSITION 1

On the center right of the front frame.
ENGINE SERIAL NO. PLATE AND POSITION 1

This is on the side face of the engine cover on the right side of the machine.
EPA: Environmental Protection Agency, U.S.A.
1-7
NECESSARY INFORMATION FOREWORD
ROPS/FOPS-CAB SERIAL NO. PLATE

This plate is located on the right inside cab on the rear beam.
AXLE SERIAL NO. PLATE

This plate is located on the right of front axle and on the left of
rear axle.
TRANSMISSION SERIAL NO. PLATE

This plate is located in travel direction front, above the
transmission output.
SEAT OPERATOR SERIAL NO. PLATE

This plate is located in front of seat, covered by the bellows.
1-8
FOREWORD NECESSARY INFORMATION
POSITION OF SERVICE METER 1

It is at the center bottom of the machine monitor.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1
Machine serial No.

Engine serial No.
Distributor name
Address
Service Personnel
Phone/Fax
1-9
CONTENTS FOREWORD
CONTENTS
FOREWORD
FOREWORD....................................................................................................................................................... 1-2
SAFETY INFORMATION.................................................................................................................................... 1-4
INTRODUCTION................................................................................................................................................. 1-6
INTENDED USE ............................................................................................................................................ 1-6
DIRECTIONS OF MACHINE ......................................................................................................................... 1-6
NECESSARY INFORMATION ........................................................................................................................... 1-7
MACHINE SERIAL NO. PLATE AND POSITION .......................................................................................... 1-7
ENGINE SERIAL NO. PLATE AND POSITION ............................................................................................. 1-7
ROPS/FOPS-CAB SERIAL NO. PLATE ........................................................................................................ 1-8
AXLE SERIAL NO. PLATE ............................................................................................................................ 1-8
TRANSMISSION SERIAL NO. PLATE .......................................................................................................... 1-8
SEAT OPERATOR SERIAL NO. PLATE ....................................................................................................... 1-8
POSITION OF SERVICE METER.................................................................................................................. 1-9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ................................................................................. 1-9
CONTENTS ...................................................................................................................................................... 1-10
DIMENSIONS, WEIGHTS AND OPERATING DATA ...................................................................................... 1-17
WA320-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA............................................................... 1-17
CE-CONFORMING EQUIPMENT..................................................................................................................... 1-18
CE-CONFORMING EQUIPMENT................................................................................................................ 1-18
MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-
H1900 ..................................................................................................................................................... 1-19
SAFETY
SAFETY LABELS............................................................................................................................................... 2-3
LOCATION OF SAFETY LABELS ................................................................................................................. 2-3
PRESENTATION OF SAFETY LABELS........................................................................................................ 2-4
GENERAL PRECAUTIONS ............................................................................................................................... 2-7
PRECAUTIONS FOR OPERATION ................................................................................................................. 2-17
STARTING ENGINE .................................................................................................................................... 2-17
OPERATION ................................................................................................................................................ 2-19
TRANSPORTATION .................................................................................................................................... 2-25
BATTERY..................................................................................................................................................... 2-26
TOWING ...................................................................................................................................................... 2-28
PRECAUTIONS FOR MAINTENANCE ............................................................................................................ 2-29
PRECAUTIONS WITH TIRES .......................................................................................................................... 2-36
OPERATION
GENERAL VIEW ................................................................................................................................................ 3-2
GENERAL VIEW OF MACHINE .................................................................................................................... 3-2
GENERAL VIEW OF CONTROLS AND GAUGES........................................................................................ 3-3
EXPLANATION OF COMPONENTS.................................................................................................................. 3-5
MACHINE MONITOR..................................................................................................................................... 3-5
MONITOR SYSTEM ................................................................................................................................. 3-6
TYPES OF WARNING .............................................................................................................................. 3-7
1-10
FOREWORD CONTENTS
CENTRAL WARNING LAMP .................................................................................................................... 3-7

CHARACTER DISPLAY PORTION .......................................................................................................... 3-8
EMERGENCY STOP ITEM .................................................................................................................... 3-14
CAUTION ITEMS.................................................................................................................................... 3-16
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.......................................................................... 3-18
INSPECTION AND MAINTENANCE ITEM............................................................................................. 3-19
PILOT DISPLAY PORTION .................................................................................................................... 3-22
METER DISPLAY PORTION.................................................................................................................. 3-25
OTHER FUNCTIONS OF MACHINE MONITOR.................................................................................... 3-27
SWITCHES .................................................................................................................................................. 3-30
CONTROL LEVERS, PEDALS .................................................................................................................... 3-39
STEERING TILT LOCK LEVER................................................................................................................... 3-43
CAP AND COVER WITH LOCK .................................................................................................................. 3-43
SAFETY BAR............................................................................................................................................... 3-44
TOWING PIN ............................................................................................................................................... 3-45
GREASE PUMP........................................................................................................................................... 3-45
CAB DOOR INNER LOCK........................................................................................................................... 3-45
CAB DOOR OPEN LOCK............................................................................................................................ 3-46
CAB WINDOW OPEN LOCK CANCEL KNOB ............................................................................................ 3-46
FUSE ........................................................................................................................................................... 3-46
FUSE CAPACITY AND NAME OF CIRCUIT.......................................................................................... 3-47
SLOW BLOW FUSE .................................................................................................................................... 3-48
POWER OUTLET ........................................................................................................................................ 3-48
STORAGE BOX........................................................................................................................................... 3-48
AIR CONDITIONER..................................................................................................................................... 3-49
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ....................................................... 3-49
METHOD OF OPERATION .................................................................................................................... 3-52
PRECAUTIONS WHEN USING.............................................................................................................. 3-53
HANDLING CAB WIPER ............................................................................................................................. 3-53
PREVENTING DAMAGE TO WIPER ARM BRACKET .......................................................................... 3-53
OPERATION..................................................................................................................................................... 3-54
CHECK BEFORE STARTING ENGINE, ADJUST....................................................................................... 3-54
WALK-AROUND CHECK ....................................................................................................................... 3-54
CHECK BEFORE STARTING ................................................................................................................ 3-57
ADJUSTMENT........................................................................................................................................ 3-63
OPERATIONS AND CHECKS BEFORE STARTING ENGINE .............................................................. 3-68
STARTING ENGINE .................................................................................................................................... 3-70
NORMAL STARTING ............................................................................................................................. 3-70
STARTING IN COLD WEATHER ........................................................................................................... 3-72
OPERATIONS AND CHECKS AFTER STARTING ENGINE ...................................................................... 3-74
BREAKING-IN THE MACHINE............................................................................................................... 3-74
NORMAL OPERATION .......................................................................................................................... 3-75
STOPPING ENGINE.................................................................................................................................... 3-76
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE .................................... 3-77
MOVING THE MACHINE........................................................................................................................ 3-77
CHANGING DIRECTION........................................................................................................................ 3-79
STOPPING THE MACHINE.................................................................................................................... 3-81
TURNING..................................................................................................................................................... 3-82
EMERGENCY STEERING ..................................................................................................................... 3-83
OPERATION OF WORK EQUIPMENT ....................................................................................................... 3-84
WORK POSSIBLE USING WHEEL LOADER ............................................................................................. 3-86
DIGGING OPERATIONS........................................................................................................................ 3-86
LEVELING OPERATIONS...................................................................................................................... 3-89
PUSHING OPERATION ......................................................................................................................... 3-89
LOAD AND CARRY OPERATIONS ....................................................................................................... 3-89
LOADING OPERATIONS ....................................................................................................................... 3-90
PRECAUTIONS FOR OPERATION ............................................................................................................ 3-92
PERMISSIBLE WATER DEPTH............................................................................................................. 3-92
IF WHEEL BRAKE DOES NOT WORK.................................................................................................. 3-92
1-11
CONTENTS FOREWORD
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES .................................................................. 3-92

ADJUSTING WORK EQUIPMENT POSTURE............................................................................................ 3-94
ADJUSTING BOOM KICKOUT............................................................................................................... 3-94
ADJUSTING BUCKET POSITIONER..................................................................................................... 3-95
BUCKET LEVEL INDICATOR ................................................................................................................ 3-95
PARKING MACHINE ................................................................................................................................... 3-96
CHECK AFTER STOPPING ENGINE ......................................................................................................... 3-97
CHECKS AFTER COMPLETION OF OPERATION .................................................................................... 3-97
LOCKING ..................................................................................................................................................... 3-98
HANDLING THE TIRES............................................................................................................................... 3-99
PRECAUTIONS WHEN HANDLING TIRES ........................................................................................... 3-99
TIRE PRESSURE ................................................................................................................................... 3-99
PRECAUTIONS FOR USING LOAD AND CARRY METHOD.............................................................. 3-100
TRANSPORTATION....................................................................................................................................... 3-101
TRANSPORTATION PROCEDURE .......................................................................................................... 3-101
LOADING, UNLOADING WORK WITH TRAILERS................................................................................... 3-101
LOADING .............................................................................................................................................. 3-101
SECURING MACHINE ......................................................................................................................... 3-102
UNLOADING......................................................................................................................................... 3-103
LIFTING MACHINE.................................................................................................................................... 3-104
LOCATION OF LIFTING POSITION MARK ......................................................................................... 3-105
WEIGHT TABLE ................................................................................................................................... 3-105
LIFTING PROCEDURE ........................................................................................................................ 3-106
COLD WEATHER OPERATION .................................................................................................................... 3-107
PRECAUTIONS FOR LOW TEMPERATURE ........................................................................................... 3-107
FUEL AND LUBRICANTS .................................................................................................................... 3-107
COOLANT............................................................................................................................................. 3-107
BATTERY ............................................................................................................................................. 3-108
PRECAUTIONS AFTER COMPLETION OF WORK ................................................................................. 3-108
AFTER COLD WEATHER ......................................................................................................................... 3-109
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER ................. 3-109
LONG-TERM STORAGE................................................................................................................................ 3-110
BEFORE STORAGE.................................................................................................................................. 3-110
DURING STORAGE .................................................................................................................................. 3-110
AFTER STORAGE..................................................................................................................................... 3-110
TROUBLESHOOTING.................................................................................................................................... 3-111
WHEN MACHINE RUNS OUT OF FUEL................................................................................................... 3-111
TOWING THE MACHINE........................................................................................................................... 3-111
WHEN ENGINE CAN BE USED........................................................................................................... 3-112
WHEN ENGINE CANNOT BE USED ................................................................................................... 3-112
IF BATTERY IS DISCHARGED ................................................................................................................. 3-113
REMOVAL AND INSTALLATION OF BATTERY.................................................................................. 3-113
PRECAUTIONS FOR CHARGING BATTERY ..................................................................................... 3-114
STARTING ENGINE WITH BOOSTER CABLE ................................................................................... 3-115
OTHER TROUBLE..................................................................................................................................... 3-117
ELECTRICAL SYSTEM ........................................................................................................................ 3-117
CHASSIS .............................................................................................................................................. 3-118
ENGINE ................................................................................................................................................ 3-120
MAINTENANCE
GUIDES TO MAINTENANCE ............................................................................................................................. 4-2
OUTLINES OF SERVICE ................................................................................................................................... 4-4
HANDLING OIL, FUEL, COOLANT, GREASE AND CARRYING OUT KOWA (Komatsu Oil Wear Analysis)4-4
OIL ............................................................................................................................................................ 4-4
FUEL......................................................................................................................................................... 4-4
COOLANT................................................................................................................................................. 4-5
1-12
FOREWORD CONTENTS
GREASE ................................................................................................................................................... 4-5

CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ........................................................................... 4-5
STORING OIL AND FUEL ........................................................................................................................ 4-6
FILTERS ................................................................................................................................................... 4-6
BIODEGRADABLE HYDRAULIC OIL AND LUBRICANTS ...................................................................... 4-7
OUTLINE OF ELECTRIC SYSTEM............................................................................................................... 4-7
WEAR PARTS .................................................................................................................................................... 4-8
WEAR PARTS LIST....................................................................................................................................... 4-8
FUEL, COOLANT AND LUBRICANTS.............................................................................................................. 4-9
LUBRICATION CHART ................................................................................................................................. 4-9
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ............................................................ 4-10
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................................................................... 4-15
TORQUE LIST ............................................................................................................................................. 4-15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ........................................................................ 4-16
MAINTENANCE SCHEDULE CHART ............................................................................................................. 4-17
MAINTENANCE SCHEDULE CHART......................................................................................................... 4-17
SERVICE PROCEDURE .................................................................................................................................. 4-19
INITIAL 250 HOURS SERVICE ................................................................................................................... 4-19
WHEN REQUIRED ...................................................................................................................................... 4-20
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT ................................................................. 4-20
DUST PRE-EXTRACTOR "TURBO II": CHECK, CLEAN....................................................................... 4-22
CLEAN INSIDE OF COOLING SYSTEM................................................................................................ 4-23
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL ............................................................................ 4-26
CHECK AXLE OIL LEVEL, ADD OIL...................................................................................................... 4-27
CLEAN AXLE CASE BREATHER .......................................................................................................... 4-28
CLEAN AIR CONDITIONER CONDENSER........................................................................................... 4-29
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID.................................................................... 4-29
CLEAN RADIATOR FINS AND COOLER FINS ..................................................................................... 4-30
CLEAN TRANSFER OIL COOLER FINS ............................................................................................... 4-31
CHECK ELECTRICAL INTAKE AIR HEATER........................................................................................ 4-31
REPLACE BOLT ON CUTTING EDGE .................................................................................................. 4-32
REPLACE BUCKET TEETH................................................................................................................... 4-33
CHECK AIR CONDITIONER .................................................................................................................. 4-34
REPLACE SLOW BLOW FUSE ............................................................................................................. 4-35
SELECTION AND INSPECTION OF TIRES .......................................................................................... 4-36
CHECK BEFORE STARTING ..................................................................................................................... 4-38
EVERY 50 HOURS SERVICE ..................................................................................................................... 4-39
DRAIN WATER, SEDIMENT FROM FUEL TANK.................................................................................. 4-39
EVERY 100 HOURS SERVICE ................................................................................................................... 4-40
LUBRICATE REAR AXLE PIVOT PIN.................................................................................................... 4-40
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER........................................................... 4-40
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ........................................................................... 4-41
CHECK BATTERY ELECTROLYTE LEVEL........................................................................................... 4-42
CHECK PARKING BRAKE ..................................................................................................................... 4-44
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST ............................................ 4-44
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN ........................................................................ 4-45
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER ................................................ 4-46
LUBRICATING........................................................................................................................................ 4-46
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ........................... 4-48
REPLACE FUEL FILTER CARTRIDGE ................................................................................................. 4-49
CLEAN WATER SEPARATOR STRAINER............................................................................................ 4-50
EVERY 1000 HOURS SERVICE ................................................................................................................. 4-51
CHANGE OIL IN TRANSFER CASE ...................................................................................................... 4-51
CLEAN TRANSFER CASE BREATHER ................................................................................................ 4-52
REPLACE HST OIL FILTER ELEMENT................................................................................................. 4-53
LUBRICATING........................................................................................................................................ 4-54
CHECK TIGHTENING PARTS OF TURBOCHARGER.......................................................................... 4-54
1-13
CONTENTS FOREWORD
CHECK PLAY OF TURBOCHARGER ROTOR...................................................................................... 4-54

CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT........................................... 4-54
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT ............................. 4-55
REPLACE HYDRAULIC TANK BREATHER ELEMENT ........................................................................ 4-56
CLEANING THE STRAINER OF THE BRAKE FILTER ......................................................................... 4-57
CHANGE AXLE OIL................................................................................................................................ 4-58
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER .. 4-59
CHECK ALTERNATOR, STARTING MOTOR........................................................................................ 4-59
CHECK ENGINE VALVE CLEARANCE, ADJUST ................................................................................. 4-59
CHECK BRAKE DISC WEAR ................................................................................................................. 4-59
CLEAN AND CHECK TURBOCHARGER .............................................................................................. 4-60
CHECK ACCUMULATOR GAS PRESSURE ......................................................................................... 4-60
CHECK VIBRATION DAMPER............................................................................................................... 4-60
LUBRICATING ........................................................................................................................................ 4-61
CHECK WATER PUMP .......................................................................................................................... 4-61
TECHNICAL DATA
TECHNICAL DATA ............................................................................................................................................ 5-2
NOISE EMISSION LEVELS ............................................................................................................................... 5-4
VIBRATION LEVEL............................................................................................................................................ 5-4
ATTACHMENTS, OPTIONS
SELECTING BUCKET AND TIRES ................................................................................................................... 6-2
MACHINE MONITOR WITH LOAD METER ...................................................................................................... 6-3
EXPLANATION OF COMPONENTS ............................................................................................................. 6-3
MACHINE MONITOR ............................................................................................................................... 6-3
MONITOR PANEL MODE SELECTOR SWITCH 1 .................................................................................. 6-4
MONITOR PANEL MODE SELECTOR SWITCH 2 .................................................................................. 6-4
LOAD METER CANCEL SWITCH ............................................................................................................ 6-4
LOAD METER SUB TOTAL SWITCH ...................................................................................................... 6-5
MACHINE MONITOR..................................................................................................................................... 6-6
MONITOR SYSTEM ................................................................................................................................. 6-6
TYPES OF WARNING .............................................................................................................................. 6-7
CENTRAL WARNING LAMP .................................................................................................................... 6-7
CHARACTER DISPLAY PORTION .......................................................................................................... 6-8
EMERGENCY STOP ITEM .................................................................................................................... 6-14
CAUTION ITEMS .................................................................................................................................... 6-17
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.......................................................................... 6-19
INSPECTION AND MAINTENANCE ITEM............................................................................................. 6-20
PILOT DISPLAY PORTION .................................................................................................................... 6-23
METER DISPLAY PORTION.................................................................................................................. 6-26
LOAD METER......................................................................................................................................... 6-28
OTHER FUNCTIONS OF MACHINE MONITOR .................................................................................... 6-51
HANDLING MULTI-FUNCTION LEVER .......................................................................................................... 6-58
EXPLANATION OF COMPONENTS ........................................................................................................... 6-58
WORK EQUIPMENT LEVER.................................................................................................................. 6-58
DIRECTIONAL SELECTOR SWITCH .................................................................................................... 6-59
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH ............................................................... 6-59
DIRECTIONAL SELECTOR PILOT LAMP ............................................................................................. 6-60
OPERATION ................................................................................................................................................ 6-61
USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE .............................................. 6-61
1-14
FOREWORD CONTENTS
CENTRAL LUBRICATION SYSTEM ............................................................................................................... 6-63

OPERATING THE CENTRAL LUBRICATION SYSTEM............................................................................. 6-63
DISPLAY AND CONTROL UNIT ................................................................................................................. 6-63
LED-DISPLAY......................................................................................................................................... 6-64
PUSHBUTTONS..................................................................................................................................... 6-64
CHANGING THE LUBRICATION INTERVAL TIMES.................................................................................. 6-65
INDEX
INDEX ................................................................................................................................................................. 7-3
NOTES
NOTES................................................................................................................................................................ 8-2
1-15
CONTENTS FOREWORD
1-16
FOREWORD DIMENSIONS, WEIGHTS AND OPERATING DATA
DIMENSIONS, WEIGHTS AND OPERATING DATA
WA320-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA
d
a
c
H
b
F
e
E B
D A
C WA320-5Abm
Measurements, operating data

Bucket capacity to ISO 7546 m³ 2,7
Material density t/m³ 1,8
Bucket weight without teeth kg 1.040
Static tipping load, straight kg 12.000
Static tipping load, 40° angle kg 10.355
Breakout force, hydraulic kN 134
Lifting capacity, hydraulic, on ground kN 155
Operating weight *) kg 14.040
a Reach at 45° discharge mm 990
b Dumping height at 45° discharge mm 2.855
c Lift height, hinge pin mm 3.910
d Height to upper edge of bucket mm 5.260
e Digging depth mm 105
A Overall length, bucket on ground mm 7.475
B Wheel base mm 3.030
C Bucket width mm 2.740
These values refer to machines with 20.5 R25
D Width over tyres mm 2.525
L3
E Gauge mm 2.050
F Ground clearance mm 440
*) Machine without additional counterweight
H Overall height mm 3.200
1-17
CE-CONFORMING EQUIPMENT FOREWORD
CE-CONFORMING EQUIPMENT
CE-CONFORMING EQUIPMENT
CE-conforming equipment
1 2 3 4 5 –
Load Hydraulic
Volume Weight
Type Part No. Capacity pressure
m³ kg
kg bar
419-72-H2100 2,7 1.040

419-72-H2110 2,7 1.143
419-72-H2160 2,7 1.118
419-72-H2170 2,7 2.217

Bucket WA320-5H 419-72-H2120 2,85 1.254
419-72-H2180 2,85 1.325
419-72-H2130 3,0 1.265

419-72-H2140 3,0 1.363
419-72-H2150 3,1 1.472
1
2
3
4
5
GK100392
1-18
FOREWORD CE-CONFORMING EQUIPMENT
MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING

TO DOCUMENT 421-93-H1900
The responsibility for observing valid regulations in the case of

wheel loaders with "interchangeable equipment" (e.g. bucket or
fork-lift) which was not supplied from works lies with the cus-
tomer which was subsequently fitted to the machine.
The directives for CE conformity and road-traffic registration
are deemed to have been fulfilled when the manufacturer of the
equipment confirms fulfilment of the form 421-93-H1900 along-
side.
The certification must be sent to the customer and the wheel
loader manufacturer. The CE conformity declaration for a spe-
cific wheel loader is only legally valid once this has taken place.
The dimensions X1, X2, Y1 and Y2 must be provided by the
customer for approval for use on public roads. (valid in Ger-
many)
The dimension Sh (smallest tyre radius) must be added to the
dimension D2.
The figure G (in kg) represents the maximum load (equipment
and operating load) which may act upon this point.
D2
Y2
X2
Sh
X1
Y1
A1
A2
Sh
GK100395b
1-19
1
B1
C1
2 D1
B2
D2
C2
H2
H1
Sh
J
A1
A2
d1=d2
3
Sh
b3
d2
3
d1
c
h
b4 b2
b1
GK100395
1-20
FOREWORD CE-CONFORMING EQUIPMENT
M A N U FA C T U R E R - S U P P L I E D C E - C O N F O R M I N G
EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900
WA320-5H 421-93-H1900
A1 Distance: bucket pivoting point - front axle, horizontal A1 1930
A2 Distance: bucket pivoting point - front axle, vertical
A2 1260
Sh Distance: road level - front axle
B1 Distance: driver's eye (1) - front axle, horizontal Sh 700
B2 Distance: driver's eye (1) - front axle, vertical
B1 1850
C1 Distance: centre steering wheel - centre front axle,
horizontal B2 2131
C2 Distance: center steering wheel - centre front axle,
C1 1425
vertical
D1 Distance: headlight - centre front axle, horizontal C2 1766
D2 Distance: headlight - centre front axle, vertical
D1 507
G Weight of equipment and working load
H1 Distance: bucket pivoting point - bucket upper edge, verti- D2 1323
cal (carrying position)
G 6400
H2 Distance: bucket pivoting point - vision line, vertical (carry-
ing position) H1 1347
J Distance: road level - bucket bottom edge (carrying posi-
H2 1651
tion)
X1 Distance: cutter protection - front axle, horizontal J 270
X2 Distance: cutter protection - road level, vertical
X1 2710
Y1 Distance: teeth protection - front axle, horizontal
Y2 Distance: teeth protection - road level, vertical X2 1157
b1 Bucket connection dimension, boom width inside Y1 2493
b2 Bucket connection dimension, boom arm
b3 Bucket connection dimension, tilt rod Y2 1042
b4 Bucket connection dimension, temporary size b1 1032
c Bucket connection dimension between d1 and d2, vertical
b2 108
d1 Bucket connection dimension, bolt (3) for boom
d2 Bucket connection dimension, bolt (3) for tilt rod b3 109
e Bucket connection dimension d1 - d2, horizontally dis-
b4 461,5
placed
h Distance: bucket bottom edge - boom bolt hole c 370
l Distance: centre of bolt -- centre of fastening screw
d1 75
d2 75
e 0
h 280
l 80
1 Driver’s eye
2 Vision line
3 Bolts
MICHELIN
Tyres
20.5R25 XHA
2,7 m³
Bucket
419-72-H2110
1-21
1-22
SAFETY
12
SAFETY
2-2
SAFETY SAFETY LABELS
SAFETY LABELS 2
The following safety labels are used on this machine. Be sure that you fully understand the correct position and
content of these safety labels.
Always keep all safety labels clean. When cleaning them, use soap and water. Do not use organic solvents or gas-
oline. These may cause the safety labels to peel off.
Missing or damaged safety labels must be replaced. Order the new part from your Komatsu distributor.
LOCATION OF SAFETY LABELS 2
2-3
SAFETY LABELS SAFETY
PRESENTATION OF SAFETY LABELS 2
1 Precautions before starting operation, inspec- 2 Precautions before leaving the machine
tion and maintenance (421-93-H1250) (421-93-H1290)
Sign indicates a hazard
WARNING! of unexpected moving
of stopped machine.
Read the Operator’s Lower working device

Manual before star- to ground, move safety
tung operation, inspec- lever to lock position
tion, maintenance or and take engine key
transportation. with you before leaving
machine.
3 Precautions when traveling in reverse 4 Use Komatsu oil only

(421-93-H1360) (421-93-H1390)
Sign indicates to pre-
vere severe injury or
death
Honk to alert people

nearby. Be sure no one
is on or near machine.
Use spotter if view is
obstructed.
2-4
SAFETY SAFETY LABELS
5 Do not enter (421-93-H1320) 6 Precautions for safety bar (421-93-H1330)

Sign indicates a crush
Sign indicates a crush
hazard between the
hazard between the
articulating parts of the
articulating parts of
vehicle.
vehicle.
Keep away from the

Lock vehicle with lock
vehicle when it is
bar to avoid movement
move.
during maintenance,
inspection and trans-
portation.
7 Precautions when coolant is at high tempera- 8 Precautions when oil is at high temperature
ture (421-93-H1280) (421-93-H1280)
Sign indicates a burn Sign indicates a burn

hazard from spurting hazard from spurting
hot water if radiator is hot oil if hydraulic oil
uncapped while hot. tank is uncapped while
hot.
Allow coolant to cool Allow hydraulic oil to

before removing cap. cool before removing
cap.
9 Precautions when handling battery cable 10 High pressure warning (421-93-H1300)

(421-93-H1310)
Sign indicates an elec- There is a hazard of
tric hazard from han- explosion injury.
dling the cable.
Do not disassembly the

accumulator, make
Read manual for safe holes in it, weld it cut it,
and proper handling. hit it, roll it or bring it
near flame.
2-5
SAFETY LABELS SAFETY
11 Do not climb on fender (421-93-H1400) 12 Do not open when engine is running

(09667-A0880)
Sign indicates a hazard Sign indicates a hazard
of falling. of rotating parts, such
as belt.
Do not stand on this Turn off engine before

place here. inspection and mainte-
nance.
13 “Do not come under machine“ sign 14 “Do not go under work equipment“ sign
(421-93-H1370) (421-93-H1380)
Sign indicates a hazard Sign indicate a crush
of being run over by hazard from falling off
moving vehicle. of working device.
Keep a safe distance Keep away when the

from vehicle when it is working device is
moving. raised.
16 Only start machine from driver's seat 17 Safety measures before starting work
(09842-A0481) (421-93-H1340)
2-6
SAFETY GENERAL PRECAUTIONS
GENERAL PRECAUTIONS 2
SAFETY RULES
q Only trained and authorized personnel can operate and maintain the machine.
q Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
q If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine
may be severly impaired putting yourself and everyone else on your jobsite in danger.
q When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-
stand all hand signals that are to be used.
IF ABNORMALITIES ARE FOUND
If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the abnormality has been cor-
rected.
CLOTHING AND PERSONAL PROTECTIVE ITEMS
q Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other
protruding parts.
q If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine,
so tie your hair up and be careful not to let it get caught.
q Always wear a hard hat and safety shoes. If the nature of

the work requires it, wear safety glasses, mask, gloves, ear
plugs, and safety belt when operating or maintaining the
machine.
q Check that all protective equipment functions properly

before using it.
FIRE EXTINGUISHER AND FIRST AID KIT
Always follow the precautions below to prepare for action if any

injury or fire should occur.
q The fire extinguisher can be fastened to the inside cabin
Fastening points
wall on the left.
q If, in the course of certain operations, there is danger of

fire, fire extinguishers must be at hand. Familiarise with the
use of the fire extinguishers.
q Inform yourself on measures to be taken in the event of a

fire.
q The first-aid kit can be positioned on the right of the cabin's

interior.
q Make sure that you know all telephone numbers of the per-
sons that you need to contact in an emergency.
2-7
GENERAL PRECAUTIONS SAFETY
SAFETY FEATURES
q Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if
they are damaged.
q Understand the method of use of safety features and use them properly.
q Never remove any safety features. Always keep them in good operating condition.
KEEP MACHINE CLEAN
q If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not
use water or steam to wash the electrical system (sensors, connectors).
q If inspection and maintenance is carried out when the

machine is still dirty with mud or oil, there is a hazard that
you will slip and fall, or that dirt or mud will get into your
eyes. Always keep the machine clean.
INSIDE OPERATOR'S COMPARTMENT
q When entering the operator's compartment, always remove all mud and oil from the soles of your shoes.
If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious
accident.
q Do not leave parts or tools lying around the operator's compartment.
q Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
q Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
q Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.
2-8
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT
q Before standing up from the operator's seat (such as when

adjusting the operator's seat), always lower the work
equipment completely to the ground, set safety lock lever
Free
(1) to the LOCK position, pull parking brake lever (2) to the
LOCK position, then stop the engine.
If you accidentally touch the levers when they are not

locked, there is a hazard that the machine may suddenly
move and cause serious injury or property damage. Lock
q When leaving the machine, always lower the work equip- 9EA04394A
ment completely to the ground, set safety lock lever (1) to

the LOCK position, pull parking brake lever (2) to the
LOCK position, then stop the engine. Use the key to lock
all the equipment. Always remove the key, take it with you, Lock
and keep it in the specified place.
Free
9EA04395A
HANDRAILS AND STEPS
To prevent personal injury caused by slipping or falling off the machine, always do as follows.
q Use the handrails and steps marked by arrows in the dia-

gram on the right when getting on or off the machine.
2-9
q To ensure safety, always face the machine and maintain

three-point contact (both feet and one hand, or both hands
and one foot) with the handrails and steps to ensure that
you support yourself.
q When entering the cab, open the cab door, push the door
securely into catcher (1) to hold in position, then use the
handrail on the inside to get on the machine.
For details of the method of releasing the door lock, see

“CAB DOOR OPEN LOCK (3-46)“.
q Do not grip the control levers when getting on or off the

machine.
q Never climb on the engine hood or covers where there are

no non-slip pads.
q Never move from the step at the rear of the machine or the step at the side of the cab to stand on top of the
tire.
q Before getting on or off the machine, check the handrails and steps, and if there is any oil, grease, or mud on
them, wipe it off immediately. In addition, repair any damage and tighten any loose bolts.
q Do not get on or off the machine while holding tools in your hand.
MOUNTING AND DISMOUNTING
q Never jump on or off the machine. Never get on or off a moving machine.
q 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 seri-
ous injury.
2-10
DO NOT GET CAUGHT IN ARTICULATED PORTION
q If the clearance at the articulating portion changes, it will

lead to serious personal injury.
Do not allow anyone to come inside the articulation range.
q Never enter or put your hand, arm, or any part of your body
in the movable portion between the work equipment and
machine or between the cylinder and the work equipment.
If someone operates the control levers by mistake, the gap
between the work equipment and machine and between
the cylinder and work equipment will change, and you, your
hand, or arm will be caught and you may suffer serious
injury.
If you have to go into a movable portion, always take action
to secure the work equipment and ensure that it cannot
move.
PREVENTION OF BURNS
Hot coolant
q To prevent burns from hot water or steam spurting out

when checking or draining the coolant, wait for the water to
cool to a temperature where it is possible to touch the radi-
ator cap by hand before starting the operation. Even when
the coolant has cooled down, loosen the cap slowly to
relieve the pressure inside the radiator before removing the
cap.
Hot oil
q To prevent burns when checking or draining the oil, wait for

the oil to cool to a temperature where it is possible to touch
the plug by hand before starting the operation. Even when
the oil has cooled down, loosen the plug slowly to relieve
the internal pressure before removing the plug.
2-11
FIRE PREVENTION
q Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particu-

larly flammable and can be hazardous. To prevent fire,
always observe the following:
q Do not smoke or use any flame near fuel or oil.
q Stop the engine before refueling.
q Do not leave the machine while adding fuel or oil.
q Tighten all fuel and oil caps securely.

q Do not spill fuel on overheated surfaces or on parts of
the electrical system.
q Use well-ventilated areas for adding or storing oil and

fuel.
q Keep oil and fuel in the determined place and do not

allow unauthorized persons to enter.
q After adding fuel or oil, wipe up any spilled fuel or oil.
q When carrying out grinding or welding work on the

chassis, move any flammable materials to a safe place
before starting.
q When washing parts with oil, use a non-flammable oil.

Diesel oil and gasoline may catch fire, so do not use
them.
q Put greasy rags and other flammable materials into a

safe container to maintain safety at the work place.
q Do not weld or use a cutting torch to cut any pipes or

tubes that contain flammable liquids.
q Fire caused by accumulation of flammable material.
Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed
around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.
q Fire coming from electric wiring
Short circuits in the electrical system can cause fire.
q Always keep electric wiring connections clean and securely tightened.

q Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.
q Fire coming from hydraulic line

Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to
the hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.
2-12
q Explosion caused by lighting equipment
q When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with anti-
explosion specifications. If such lighting equipment is not used, there is danger of explosion that may
cause serious injury.
q When taking the electrical power for the lighting from the machine itself, follow the instructions in this man-
ual.
ACTION IF FIRE OCCURS

If a fire occurs, escape from the machine as follows.
q Turn the start switch OFF to stop the engine.
q Use the handrails and steps to get off the machine.
WINDOW WASHER LIQUID
Use an ethyl alcohol base washer liquid.

Methyl alcohol base washer liquid may irritate your eyes, so do not use it.
ROPS (Roll Over Protective Structure)
q The roll-over protection system (ROPS) protects the operator and absorbs load and impact energy, if the
machine should roll over.
q The ROPS is a fixed component of the cab. The machine must not be operated without this roll-over protection
system.
q The ROPS meets the regulations of all member states of the EU. If, however, the ROPS is modified, damaged,
or repaired without permission, its stability is impaired. In this case, the ROPS must be replaced, since its cor-
rect function can no longer be guaranteed.
q The ROPS can only provide maximum protection, if the driver wears the safety belt correctly. For this reason,
the safety belt is to be worn when the machine is in operation.
ATTACHMENT FOR PROTECTION AGAINST FALLING OBJECTS (FOPS)

When you work on a site where there is danger of falling rocks or other objects, the machines must be equipped
with a FOPS. If the FOPS is modified without permission or damaged, its stability is impaired. In this case, the
FOPS must be replaced, since its correct function can no longer be guaranteed.
PRECAUTIONS FOR ATTACHMENTS
q When installing optional parts or attachments, there may be problems with safety or legal restrictions. There-
fore contact your Komatsu distributor for advice.
q Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.
q When installing and using optional attachments, read the instruction manual for the attachment, and the gen-
eral information related to attachments in this manual.
UNAUTHORIZED MODIFICATION
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
q Komatsu will not be responsible for any injuries, accidents, product failures or other property damages result-
ing from modifications made without authorization from Komatsu.
2-13
SAFETY AT WORKSITE
q Before starting operations, thoroughly check the work area

for dangerous working conditions.
q Inspect the surface of the soil in the working area and

determine the optimum and safest procedure.
q When carrying out operations near combustible materials

such as thatched roofs, dry leaves or dry grass, there is a
hazard of fire, so be careful when operating.
q Determine the required safety measures against dangers

on public roads in co-operation with the owners, users, and
responsible authorities.
q On sites where there are underground water pipes, gas
pipes, or conduits for high voltage cables, contact the
responsible supply company to determine the lines' posi-
tions. Ensure that these facilities will not be damaged.
q When working with water or crossing sand banks, first

check the subsoil and depth and flow rate of the water.
Ensure that the permitted water depth will not be
exceeded.
q Take action to prevent unauthorized people from approach-

ing the jobsite.
WORKING ON LOOSE GROUND
q Do not drive the machine too close to edges of hills, overhangs, and deep ditches.
q If the soil starts to sag at these locations, the machine may tip over, fall down, or roll over, thus injuring you
severely.
q Take into account that the soil is wet and soft after heavy rainfall, or very loose after blasting.
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
injury or property damage. On jobsites where the machine may
go close to electric cables, always do as follows.
q 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.
2-14
q Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death.
Always maintain a safe distance (see the table on the right) Safety
between the machine and the electric cable. Check with Nominal Voltage
Distance
the local power company about safe operating procedure
before starting operations. up to 1000 V 1m
q To prepare for any possible emergencies, wear rubber over 1 kV up to 110 kV 3m
shoes and gloves. Lay a rubber sheet on top of the seat,
and be careful not to touch the chassis with any exposed over 110 kV up to 220 kV 4m
part of your body.
q Use a signalman to give warning if the machine

over 220 kV up to 380 kV 5m
with unknown nominal voltage 5m

approaches too close to the electric cables.
q When carrying out operations near high voltage cables, do

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

q If it is necessary to start the engine within an enclosed
area, or when handling fuel, flushing oil, or paint, open the
doors and windows to ensure that adequate ventilation is
provided to prevent gas poisoning.
CHECKING SIGNALMAN'S SIGNALS AND SIGNS
q Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
q Only one signalman should give signals.
q Make sure that all workers understand the meaning of all signals and signs before starting work.
EMERGENCY EXIT FROM OPERATOR'S CAB

Machines equipped with a cab have doors on the left and right sides. If the door on the one side does not open,
escape from the door on the other side.
2-15
BE CAREFUL ABOUT ASBESTOS DUST
Asbestos dust in the air can cause lung cancer if it is inhaled.

There is danger of inhaling asbestos when working on jobsites
handling demolition work or work handling industrial waste.
Always observe the following.
q Spray water to keep down the dust when cleaning. Do not

use compressed air for cleaning.
q If there is danger that there may be asbestos dust in the

air, always operate the machine from an upwind position.
All workers should use an approved respirator.
q Do not allow other persons to approach during the opera-
tion.
q Always observe the rules and regulations for the work site
and environmental standards.
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always
use genuine Komatsu parts.
2-16
SAFETY PRECAUTIONS FOR OPERATION
PRECAUTIONS FOR OPERATION 2
STARTING ENGINE 2
If there is a warning tag hanging from the work equipment con-
trol lever, do not start the engine or touch the levers.
9JA05370A
CHECKS BEFORE STARTING ENGINE
Carry out the following checks before starting the engine at the beginning of the day's work.
q Remove all dirt from the surface of the window glass to ensure a good view.
q Remove all dirt from the surface of the lens of the front lamps, working lamps, and rear combination lamp, and
check that they light up correctly.
q Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and
check for damage to the electric wiring.
q 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.
q Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no dam-
age or wear to the seat belt or mounting clamps.
q Check that the gauges work properly, check the angle of the lights and working lamps, and check that the con-
trol levers are all at the neutral position.
q Before starting the engine, make sure that the safety lock lever is in the LOCK position.
q Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. See “ADJUST
REAR VIEW MIRROR (3-67)“.
q Check that there are no persons or obstacles above, below, or in the area around the machine.
2-17
PRECAUTIONS FOR OPERATION SAFETY
PRECAUTIONS WHEN STARTING
q Only start and operate the machine from the seat. Never try to start the engine by hot-wiring the ignition. This
can cause fire, grave injuries or death.
q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a seri-
ous bodily injury or fire.
q When starting the engine, sound the horn as a warning.
q Do not allow anyone apart from the operator to ride on the machine.
PRECAUTIONS IN COLD AREAS
q Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.
q 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.
2-18
OPERATION 2
CHECKS BEFORE OPERATION
When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
q Always fasten your seat belt.
q Check the operation of travel, steering and brake systems,

and work equipment control system.
q Check for any abnormality in the sound of the machine,

vibration, heat, smell, or gauges; check also that there is
no leakage of oil or fuel.
q If any abnormality is found, carry out repairs immediately.
q Before driving the machine or starting operations, check

that safety bar (1) is securely fixed at the FREE position.
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE
q Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles.
q Before travelling, sound the horn to warn people in the area.
q Always operate the machine only when seated.
q Do not allow anyone apart from the operator to ride on the machine.
q Check that the back-up alarm (alarm buzzer when machine travels in reverse) works properly.
q Always lock the door and windows of the operator's compartment in position (open or closed).
On jobsites where there is a hazard of flying objects or of objects entering the operator's compartment, check
that the door and windows are securely closed.
q If there is an area to the rear of the machine which cannot

be seen, position a signal person. Take special care not to
hit other machines or people when turning or swinging the
machine.
Always be sure to carry out the above precautions even when

the machine is equipped with mirrors.
2-19
PRECAUTIONS WHEN TRAVELING
q Never turn the key in the starting switch to the OFF position. It is dangerous if the engine stops when the
machine is traveling, because the steering becomes heavy. If the engine stops, depress the brake pedal
immediately to stop the machine.
q When traveling on level ground, keep the work equipment

at height of 40 to 50 cm (16 to 20 in) from the ground.
When traveling, do not operate the work equipment control

levers. If the work equipment control levers have to be
operated, stop the machine first, then operate the levers.
q When traveling on rough ground, travel at low speed and
do not operate the steering suddenly. There is danger that
the machine may turn over. The work equipment may hit
the ground surface and cause the machine to lose its bal-
ance, or may damage the machine or structures in the
area.
q Avoid traveling over obstacles when possible. If the

machine has to travel over an obstacle, keep the work
equipment close to the ground and travel at low speed.
Never travel over obstacles which make the machine tilt
strongly to one side.
q When traveling or carrying out operations, always keep a

safe distance from people, structures, or other machines to
avoid coming into contact with them.
q When passing over bridges or structures, check first that
the structure is strong enough to support the weight of the
machine. When traveling on public roads, check first with
the relevant authorities and follow their instructions.
q When operating in tunnels, under bridges, under electric

wires, or other places where the height is limited, operate
slowly and be extremely careful not to let the work equip-
ment hit anything.
q Always obey the traffic regulations when traveling on public

roads. This machine travels at a lower speed than normal
automobiles, so keep to the side of the road and be careful
to leave the center of the road free for other vehicles.
q If you drive the machine at high speed continuously for a
long time, the tires will overheat and the internal pressure
will become abnormally high. This may cause the tires to
burst. If a tire bursts, it produces an extremely large
destructive force, and this may cause serious injury or acci-
dent.
If you are going to travel continuously, please consult your

Komatsu distributor.
2-20
TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side, always do as follows.
q When traveling on slopes, keep the bucket at height “A“ of

approximately 20 to 30 cm (8 to 12 in) above the ground.
In case of emergency, quickly lower the bucket to the
ground to help the machine to stop.
q Always travel straight up or down a slope. Traveling at an

angle or across the slope is extremely dangerous.
q Do not turn on slopes or travel across slopes. Always go

down to a flat place to change the position of the machine,
then travel on to the slope again.
q Travel on grass, fallen leaves, or wet steel plates with low speed. Even with slight slopes there is a hazard
that the machine may slip.
q If the engine stops, depress the brake pedal immediately, lower the bucket to the ground, and apply the park-
ing brake to stop the machine.
q When traveling downhill, never shift gear or place the transmission at neutral. It is dangerous not to use the
braking force of the engine. Always place the transmission in a low gear before starting to travel downhill.
q When traveling downhill, travel slowly. If necessary, use the braking force of the engine together with the brake
pedal to control the travel speed.
q When traveling up or down hills with a loaded bucket, always travel with the bucket facing uphill. If the
machine travels with the bucket facing downhill, there is danger that the machine may tip over.
2-21
PROHIBITED OPERATIONS
q It is dangerous to excavate the bottom of a rock face.

Never do this.
q It is dangerous to use the bucket or lift arm for crane oper-

ations, so do not carry out such operations.
q Do not pass the bucket over the head of other workers or

over the operator's seat of dump trucks or other hauling
equipment. The load may spill or the bucket may hit the
dump truck and cause serious injury or property damage.
EMERGENCY LOWERING SYSTEM
When the engine is not running, you can lower the work unit by
means of the pilot control lever.
q PPC control lever
To achieve this, slowly press the pilot control lever (2) forward 2
to the "LOWER" position.
9JA05377-2A
q EPC control lever 2

1. Turn the key in ignition switch (1) to ON.
2. Then slowly press the pilot control lever (2) forward to the
"LOWER" position.
1
9JA05377-1A
2-22
PRECAUTIONS WHEN OPERATING
q When using the machine, to prevent the machine from overturning due to overloading and to avoid damage to
the work equipment, do not exceed the maximum permitted load or performance of the machine.
q If the engine cannot be started again after it has stopped, immediately operate the work equipment control
levers to lower the work equipment to the ground. (After the engine stops, the accumulator allows the work
equipment to be operated for a limited time.)
q 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.
q 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.
q When the bucket is fully loaded, never start, turn, or stop

the machine suddenly. There is danger of the machine
turning over.
q When handling unstable loads, such as round or cylindrical

objects, or piled sheets, if the work equipment is raised
high, there is danger that the load may fall on top of the
operator' compartment and cause serious injury or dam-
age.
q When handling unstable loads, be careful not to raise the

work equipment too high or tip the bucket back too much.
q If the work equipment is suddenly lowered or suddenly

stopped, the reaction may cause the machine to tip over.
Particularly when carrying a load, be sure to operate the
work equipment carefully.
q When operating in tunnels, under bridges, under electric

wires, or other places where the height is limited, be
extremely careful not to let the work equipment hit any-
thing.
q To prevent accidents caused by hitting other objects,

always operate the machine at a speed which is safe for
operation, particular in confined spaces, indoors, and in
places where there are other machines.
METHODS OF USING BRAKE

q When the machine is traveling, do not rest your foot on the brake pedal. If you travel with your foot resting on
the pedal, the brake will always be applied, and this will cause the brakes to overheat and fail.
q Do not depress the brake pedal repeatedly if not necessary.
q When traveling downhill, use the braking force of the engine. If necessary, use the brake pedal at the same
time.
2-23
OPERATE CAREFULLY ON SNOW
q When working on snow or ice-covered surfaces, there is danger of the machine starting to skid even at a very
flat angle. For this reason, drive slowly and avoid sudden starts, turns, or stops.
q When driving on hill flanks covered with snow do not brake abruptly to stop the machine. To stop the machine,
lower the bucket onto the ground.
q The load may vary considerably, depending on the structure of the snow. For this reason, reduce the load and
pay attention that the machine does not start to skid.
q When traveling on snow-covered roads, always fit tire chains.
PARKING MACHINE
q Park the machine on firm, level ground.
q Select a place where there is no hazard of falling rocks or

landslides, or of flooding if the land is low.
q Lower the work equipment completely to the ground.
q When leaving the machine, set safety lock lever (1) to the
LOCK position, pull parking brake lever (2) to the LOCK
position, then stop the engine.
q Lock all points that can be locked and store the key in a
safe place.
q When parking the machine on public roads, ensure that it

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

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

under the wheels to prevent the machine from moving.
2-24
TRANSPORTATION 2
The machine can be divided into parts for transportation, so when transportating the machine, please contact your
Komatsu distributor to have the work carried out.
LOADING AND UNLOADING
When loading or unloading the machine, mistaken operation

may bring the hazard of the machine tipping over or falling, so
particular care is necessary. Always do as follows.
q Perform loading and unloading on firm, level ground only.

Maintain a safe distance from the edge of the road or cliff. Ramp
q Always use ramps of adequate strength. Be sure that the
ramps are wide, long, and thick enough to provide a safe Blocks
loading slope. Take suitable steps to prevent the ramps Distance
from moving out of position or coming off. Block
between ramps
q Be sure the ramp surface is clean and free of grease, oil,
9ER01312A
ice and loose materials. Remove dirt from machine-tracks.

On a rainy day, in particular, be extremely careful since the
ramp surface is slippery.
q Run the engine at low speed and travel slowly.
q Never correct your steering on the ramps. If necessary, drive off the ramps, correct the direction, then enter
the ramps again.
q When loading or unloading to an embankment or platform, make sure that it has suitable width, strength, and
grade.
q For machines equipped with a cab, always lock the door after boarding the machine. If this is not done, the
door may suddenly open during transportation.
Refer to “TRANSPORTATION (3-101)“.
SHIPPING
When shipping the machine on a trailer, do as follows.
q The weight, transportation height, and overall length of the machine differ according to the work equipment, so
be sure to confirm the dimensions.
q When passing over bridges or structures on private land, check first that the structure is strong enough to sup-
port the weight of the machine. When traveling on public roads, check first with the relevant authorities and fol-
low their instructions.
q Lock the frame with the safety bar to prevent the machine from articulating.
q For details of the shipping procedure, see “TRANSPORTATION (3-101)“ in the OPERATION section.
2-25
BATTERY 2
BATTERY HAZARD PREVENTION
Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode.
Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions.
q Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may
cause an explosion. Always check the battery electrolyte level periodically and add distilled water to bring the
electrolyte level to the UPPER LEVEL line.
q When working with batteries, always wear safety glasses and rubber gloves.
q Never smoke or use any flame near the battery.
q If you spill acid on your clothes or skin, immediately flush

the area with large amount of water.
q If acid gets into your eyes, flush them immediately with

large amount of water and seek medical attention.
q Before working with batteries, turn the starting switch to the OFF position.
As there is a hazard that sparks will be generated, always do as follows.
q Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.
q Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last.
q Attach the battery terminal securely.
q Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
q Tighten the battery caps securely.
q Install the battery securely to the determined place.
2-26
STARTING WITH BOOSTER CABLES
If any mistake is made in the method of connecting the booster

cables, it may cause the battery to explode, so always do as
follows.
q When starting with a booster cable, carry out the starting

operation with two workers (one worker sitting in the opera-
tor's seat and the other working with the battery).
q When starting from another machine, do not allow the two

machines to touch.
q When connecting the booster cables, turn the starting
switch OFF for both the normal machine and problem
machine. There is a hazard that the machine will move
when the power is connected.
q Be sure to connect the positive (+) cable first when install-

ing the booster cables. Disconnect the negative (-) cable
(ground side) first when removing them.
q When removing the booster cables, be careful not to let the

booster cable clips touch each other or to let the clips touch
the machine.
q Always wear safety goggles and rubber gloves when start-
ing the engine with booster cables.
q When connecting a normal machine to a problem machine

with booster cables, always use a normal machine with the
same battery voltage as the problem machine.
q For details of the starting procedure when using booster

cables, see “STARTING ENGINE WITH BOOSTER
CABLE (3-115)“ in the OPERATION section.
2-27
TOWING 2
WHEN TOWING
Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selec-
tion or inspection of the wire rope.
For towing, see “TOWING THE MACHINE (3-111)“.
q Always wear leather gloves when handling wire rope.
q During the towing operation, never stand between the tow-

ing machine and the machine being towed.
q Never tow a machine on a slope.
q Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope
may break during the towing operation.
2-28
SAFETY PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR MAINTENANCE 2

WARNING TAG
q Always attach the “DO NOT OPERATE“ warning tag to the

work equipment control lever in the operator's cab to alert
others that you are performing service or maintenance on
the machine. Attach additional warning tags around the
machine if necessary.
Keep this warning tag in the tool box while it is not used. If
there is not the tool box, keep the tag in the operation man-
ual pocket.
9JA05370A
q If others start the engine, or touch or operate the work

equipment control lever while you are performing service
or maintenance, you could suffer serious injury or property
damage.
KEEP WORK PLACE CLEAN AND TIDY
Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances
that will cause you to slip. Always keep the work place clean the tidy to enable you to carry out operations safely.
If the work place is not kept claen and tidy, there is the danger that you will trip, slip, or fall over and injure yourself.
APPOINT LEADER WHEN WORKING WITH OTHERS
When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.
When working with others, misunderstandings between workers can lead to serious accidents.
2-29
PRECAUTIONS FOR MAINTENANCE SAFETY
MAINTENANCE WITH ENGINE RUNNING
q Stop the machine on firm, level ground.
q Select a place where there is no hazard of falling rocks or

landslides, or of flooding if the land is low.
q Lower the work equipment completely to the ground and

stop the engine.
q After stopping the engine, operate work equipment control

lever (1) 2 to 3 times fully to the RAISE and LOWER posi-
tions to release the pressure inside the hydraulic circuit,
then set safety lock lever (2) to the LOCK position.
q Pull parking brake lever (3) to the LOCK position, then put
blocks under the front and the rear of the tires.
q Lock the front and rear frames with safety bar (4).
2-30
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with
the engine running, carry out the operation with at least two workers and do as follows.
q 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.
q When carrying out operations near the fan, fan belt, or

other rotating parts, there is a hazard of being caught in the
parts, so be careful not to come close.
q Never drop or insert tools or other objects into the fan or
fan belt. Parts may break or be sent flying.
q Set safety lock lever (1) to the LOCK position to prevent

the work equipment from moving. Then pull parking brake
lever (2) to the position to prevent the machine from mov-
ing.
q Do not touch any control levers. If any control lever must

be operated, give a signal to the other workers to warn
them to move to a safe place.
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF
For machines equipped with a E.C.S.S. lower the bucket to the ground, turn the E.C.S.S. switch OFF, and stop the
engine before starting inspection or maintenance. NEVER turn the switch ON during inspection or maintenance.
PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.
2-31
ACCUMULATOR
WARNING
Danger of injury! Pressure accumulator is filled with highly
pressurised nitrogen.
Do not open or damage the pressure accumulator.
The accumulator is charged with high-pressure nitrogen gas.

When handling the accumulator, careless procedure may
cause an explosion which could lead to serious injury or prop-
erty damage. For this reason, always observe the following
precautions.
q Do not disassemble the accumulator.
q Do not bring it near flame or dispose of it in fire.
q Do not make holes in it, weld it, or use a cutting torch.
q Do not hit or roll the accumulator, or subject it to any

impact.
q When disposing of the accumulator, the gas must be
released. Please contact your Komatsu distributor to have
this work performed.
PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the
area. If necessary, employ an observer.
ATTACHMENTS
q Appoint a leader before starting removal or installation

operations for attachments.
q Place attachments that have been removed from the

machine in a stable condition so that they do not fall. And
take steps to prevent unauthorized persons from entering
the storage area.
2-32
WORKING UNDER THE RAISED BOOM
WARNING
Danger of injury! The raised boom may suddenly fall! For
safety reasons, a raised boom must be secured against
dropping before you pass or stand under it.
q The boom must be secured against moving if any work is

to be carried out under it when it is in a raised position. For
this purpose you should use a supporting prop (1) which is
to be positioned below the boom.
q Park the machine on level, solid ground.
q Apply the parking brake.
q Place wheel chocks in front of the wheels to prevent the Free

machine from inadvertently rolling away.
q Lift the arm far enough to allow the supporting prop to be

placed beneath the boom.
q Switch off the engine. Lock
q With the engine switched off, lower the boom slowly until it
9EA04401A
rests on the supporting prop.
q Set the control lever to "NEUTRAL" and secure it with the

safety lever (2) (locked).
PRECAUTIONS WHEN USING HAMMER
When using a hammer, pins may fly out or metal particles may
be scattered. This may lead to serious injury. Always do as
follows.
q If hard metal parts such as pins, bucket teeth, cutting

edges, or bearings are hit with a hammer, there is a hazard
that pieces might be scattered and cause injury. Always
wear safety goggles and gloves.
q When hitting pins or bucket teeth, there is a hazard that

broken pieces might be sent flying and injure people in the
surrounding area. Always check that there is no one in the
surrounding area.
q There is a hazard that the pin hit with strong force may fly
out and injure people in the surrounding area.
REPAIR WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equip-
ment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.
REMOVING BATTERY TERMINAL

When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of
the battery to prevent the flow of current.
2-33
PRECAUTIONS WITH HIGH-PRESSURE OIL
The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always
check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to
serious injury, so always do as follows.
q When carrying out inspection and maintenance of the pressure, release the pressure before starting. For
details, see “MAINTENANCE WITH ENGINE RUNNING (2-30)“. Do not carry out inspection or replacement
work with the circuit under pressure.
q If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the
piping and hoses and for swelling in the hoses.
When carry out inspection, wear safety glasses and leather gloves.
q There is a hazard that high-pressure oil leaking from small

holes may penetrate your skin or cause blindness if it con-
tacts your eyes directly. If you are hit by a jet of high-pres-
sure oil and suffer injury to your skin or eyes, wash the
place with clean water, and consult a doctor immediately
for medical attention.
HANDLING HIGH-PRESSURE HOSES
q If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury or property damage. If any loose bolts are found, stop work and tighten to the specified torque.
q If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor.
q Replace all hoses every 2 years at the latest. The shelf life of the hose should not exceed 2 years.
q Hoses must be replaced as soon as the following damage is noticeable:
q damage to the outer layer through to the intermediate layer,
q brittleness in the outer layer,
q distortions in pressurised or unpressurised state not conforming with the original shape of the installed hose,
q leakages,
q damage to the hose fittings or to the connection between fittings and hose,
q storage damage.
q When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.
q See also "PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (4-16)".
2-34
WASTE MATERIALS
To prevent pollution, pay careful attention to the method of disposing of waste materials.
q Always put oil drained from your machine in containers.

Never drain oil directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
q Obey appropriate laws and regulations when disposing of

harmful objects such as oil, fuel, coolant, solvent, filters,
and batteries.
MAINTENANCE OF AIR CONDITIONER
If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frost-
bite.
Never touch refrigerant.
COMPRESSED AIR
q When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.
q When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,
and other protective equipment.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
q In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service
and maintenance at periodic intervals. In order to further increase safety, components with a strong relation-
ship to safety, such as hoses and seat belts, must be replaced at periodic intervals.
Replacement of safety critical parts: See “PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (4-
16)“.
q The material of these components naturally changes over time, and repeated use causes deterioration, wear,
and fatigue. As a result, there is a hazard that these components may fail and cause serious injury or death.
It is difficult to judge the remaining life of these components from external inspection or the feeling when oper-
ating, so always replace them at the specified interval.
q Replace or repair safety-critical parts if any defect is found, even when they have not reached the time speci-
fied interval.
q Replace all hoses every 2 years at the latest. The shelf life of the hose should not exceed 2 years.
2-35
PRECAUTIONS WITH TIRES SAFETY
PRECAUTIONS WITH TIRES 2

HANDLING TIRES
See also “HANDLING THE TIRES (3-99)“.
If tires or rims are handled mistakenly, there is danger that the

tire may explode or be damaged, or that the rim may fly off and
cause serious injury or death.
To maintain safety, always do as follows.
q Maintenance, disassembly, repair, and assembly of the

tires and rims requires special equipment and special tech-
nology, so always ask your Komatsu distributor to carry out
these operations.
q Inflate tyres up to the defined pressure. If the tyre pressure

is too low, the tyres may heat up and burst. If the tyre pres-
sure is too high, there is also danger that the tyre may
burst.
q If a tyre heats up considerably, inflammable gases are pro-
duced. A burning tyre may burst very easily, thus spreading
fire over a large area.
q Check the tyre pressure when the tyres are still cold. Do
not let off pressure, when the pressure in a warm tyre has
increased.
q Do not light a fire and do not carry out welding near the
tyre.
q Keep the working area free of pointed or sharp objects that

may damage the tyre.
q Avoid any overload.
q The values for tyre pressure and permitted speed given in

this manual correspond to the manufacturers' values. See
also "HANDLING THE TIRES (3-99)".
q For details, please refer to your Komatsu distributor or the

tyre manufacturer.
PRECAUTIONS WHEN STORING TIRES

Tires for construction equipment are extremely heavy, so they
q Basically, tyres must be stored in a protected room that

may cause serious personal injury.
cannot be accessed by unauthorised persons.
q Place the tyres on an even surface and incline them 60° to

Block
70° against a solid stopper. Secure the tyres with wheel

chocks so that they cannot roll away, tip over, or slip.
q If, however, a tyre tips over despite this safety measure, do

not try to stop it, but get out of the way as quickly as possi- AW63748-A
ble, since tyres for construction machines are very heavy
and may cause serious injuries.
2-36
OPERATION
13
GENERAL VIEW OPERATION
GENERAL VIEW 3
GENERAL VIEW OF MACHINE 3
(1) Bucket (8) Turn signal lamp

(2) Tilt lever (9) Head lamp
(3) Front wheel (10) Lift cylinder
(4) Bucket cylinder (11) Lift arm
(5) Front working lamp (12) Rear working lamp
(6) ROPS cab (13) Rear combination lamp
(7) Rear wheel
3-2
OPERATION GENERAL VIEW
GENERAL VIEW OF CONTROLS AND GAUGES 3
(1) Parking brake lever (15) Lift arm control lever
(2) Rear wiper switch (16) Directional selector switch
(3) Front wiper switch (17) Variable shift control switch
(4) Front working lamp switch (18) Speed range selector switch
(5) Rear working lamp switch (19) Starting switch
(6) Hazard lamp switch (20) Traction control switch
(7) Directional lever (21) E.C.S.S. switch (option)
(8) Horn switch (22) Directional selector switch actuation switch
(9) Steering wheel (23) Safety lock lever

(10) Lamp switch (24) Accelelator pedal
(10) Turn signal lever (25) Brake pedal
(10) Dimmer switch (26) Rear heated wire glass switch
(11) Monitor panel mode selector switch 1 (27) Air conditioner panel
(12) Monitor panel mode selector switch 2 (28) Radio
(13) Cigarette lighter (29) Room lamp switch

(14) Bucket control lever
3-3
GENERAL VIEW OPERATION
MACHINE MONITOR
(1) Pilot lamp for speed range selector switch position (14) Parking brake reminder caution lamp
(2) Steering oil pressure caution lamp (15) Axle oil temperature caution lamp
(3) Emergency steering pilot lamp (16) Engine oil level caution lamp
(4) Preheating pilot lamp (17) Air cleaner clogging caution lamp
(5) Directional lever position pilot lamp (18) Radiator coolant level caution lamp
(6) HST oil temperature gauge (19) Maintenance caution lamp
(7) Engine coolant temperature gauge (20) HST oil filter clogging caution lamp
(8) Speedometer (21) Battery charge circuit caution lamp
(9) Turn signal pilot lamp (22) Engine oil pressure caution lamp
(10) Head lamp high beam pilot lamp (23) Central warning lamp
(11) Fuel gauge (24) Meter display pilot lamp
(12) Parking brake pilot lamp (25) Character display
(13) Brake oil pressure caution lamp
3-4
OPERATION EXPLANATION OF COMPONENTS
EXPLANATION OF COMPONENTS 3
The following is an explanation of the devices needed for operating the machine.
To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the
equipment and the meanings of the displays.
MACHINE MONITOR 3
A: Character display E: Pilot display
B: Emergency stop items F: Meter display

C: Caution items G: Central warning lamp
D: Inspection and maintenance items
3-5
EXPLANATION OF COMPONENTS OPERATION
MONITOR SYSTEM 3
TESTING ACTUATION OF MACHINE MONITOR SYSTEM
NOTICE
When the starting switch is in the ON position before start-
ing the engine, lamps (1) in the diagram on the right light
up for approx. 3 seconds and the alarm buzzer sounds for
approx. 3 seconds.
After 3 seconds all lamps except lamps (2) go out.
Lamps (2) go out after the engine starts.
If any lamps do not light up there is probably a failure or a
disconnection, so please ask your Komatsu distributor to
carry out inspection.
q When the starting switch is turned ON, if the directional

lever is not at the neutral position, the central warning lamp
lights up and the alarm buzzer sounds intermittently. If this
happens, return the directional lever to the neutral position.
The lamp will go out and the buzzer will stop.
q Directional lever (6): Neutral position

6
Directional selector actuation switch (3): ON position
Directional selector switch (4): Forward or Reverse position
When the starting switch is turned to the ON position with

the levers and switches as above described, all directional
lever positional pilot lamps (5) will go out.
If directional selector switch (4) is then set to the N posi-

tion, directional lever positional pilot lamps (5) display the 9JA04477A
normal condition “N“.
3-6
TYPES OF WARNING 3
If an abnormality occurs on the machine, or if any switch or

lever is operated accidently, the monitor display and buzzer
give a warning to inform the operator.
Following are the types of warning depending on the level of

danger.
REMARK
For details of action codes “E03“ to “E00“, see “ACTION CODE
DISPLAY (3-9)“.
EMERGENCY STOP
This warning is given if there is a serious failure that affects the normal operation of the machine or if the setting is
incorrect.
The central warning lamp on the monitor and the caution lamp for the location of the abnormality light up, and at
the same time, the alarm buzzer sounds and action code “E03“ is displayed on character display (1).
CAUTION
This warning is given if the cooling water or lubricating oil overheat.

The central warning lamp on the monitor and the individual caution lamps light up, and at the same time, the alarm
buzzer sounds and action code “E02“ is displayed on character display (1).
MISTAKEN OPERATION
This warning is given if any switch or lever is operated mistakenly.
The central warning lamp on the monitor lights up and the alarm buzzer sounds at the same time. In addition, if
the travel speed is too high, action code “E00“ is displayed on character display (1).
INSPECTION AND MAINTENANCE
This warning is given if it is necessary to carry out inspection and maintenance of wear parts, or if it is necessary to
check the oil or cooling water level.
The individual caution lamp on the monitor lights up, and at the same time, action code “E01“ is displayed on
character display (1).
In the case of this warning, the central warning lamp does not light up and the alarm buzzer does not sound.
CENTRAL WARNING LAMP 3
This display portion (1) lights up if any emergency stop item,

caution item, or mistaken operation of any switch or lever
occurs. At the same time, the alarm buzzer sounds.
Check the content of the display and carry out the specified
action for the item.
3-7
CHARACTER DISPLAY PORTION 3
(1) Service meter (4) Filter, oil replacement time display
(2) Action code display
(3) Failure code display
Normally, the service meter is displayed on the character display.
If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out
inspection and maintenance, an action code is displayed to recommend suitable action.
When the time for replacing the filter or changing the oil is reached, after completion of the system check with the
starting switch at the ON position, the maintenance monitor caution lamps flash or light up, and at the same time,
the filter or oil to be replaced is displayed.
NOTICE
Information regarding the failure of the machine or maintenance is displayed on the character display
when the starting switch is at the ON position, check the display to confirm that there is no abnormality
before starting to travel.
SERVICE METER
This meter (1) shows the total time that the machine has been
operating.
While the engine is running, the service meter advances even if

the machine is not moving.
The meter advances by 1 for every hour of operation, regard-
less of the engine speed.
Even if the starting switch is at the OFF position, the service

meter will display as long as the top part ( ) of monitor panel
mode selector switch 1 is being pressed.
3-8
NOTICE
When the starting switch is at the OFF position, if the service meter is displayed even though the top ( )
of monitor panel mode selector switch 1 is not being pressed, there is probably a failure in the machine,
so please contact your Komatsu distributor for inspection.
ACTION CODE DISPLAY
WARNING
If action code E03 is displayed, stop the machine immediately and check the failure code. For details, see
“FAILURE CODE DISPLAY (3-11)“.
Inform your Komatsu distributor of the failure code and ask for repairs.
If there is a failure on the machine, or it is necessary to change the method of operation, or if inspection or mainte-
nance must be carried out, action code E00, E01, E02, or E03 is displayed on the character display in display por-
tion.
If different failures occur at the same time, the action code for the more serious problem is displayed.
The level of seriousness is as follows, starting with the most serious: E03, E02, E01, E00.
In the case of action codes E00, E02, and E03, the alarm buzzer sounds intermittently and the central warning
lamp lights up.
If action codes E00, E01, E02, or E03 are displayed on the character display, stop operations, check the content
of the display, and take the following action.
E03: When this code is displayed, stop the machine immedi-

ately, check the failure code, and contact your Komatsu distrib-
utor for repairs.
REMARK
“E03 CALL“ is displayed on the character display, and then
“CHECK RIGHT NOW“ and “E03 CALL“ are displayed in turn
for 3 seconds each.
E02: If overrun related information is displayed, reduce the

engine speed and the speed of the machine while continuing
operations.
If the overheat related display is given, stop the machine and

run the engine under no load at a mid-range speed.
If an action code is still displayed after doing this, check the fail-
ure code and contact your Komatsu distributor for repairs.
REMARK
“E02“ is displayed on the character display, and then the condi-
tion of the machine related to the overheating or overrun is dis-
played in turn with “E02“ for 3 seconds each.
3-9
E01: When a failure occurs in the mechanical system, such as

a drop in the level of the engine cooling water, the maintenance
location is displayed. If the maintenance caution lamp lights up
at the same time, carry out inspection and maintenance of the
item indicated after completion of the day's work or when
changing shifts. If “MAINTENANCE“ is displayed together with
E01, check the failure code and ask for repairs to be carried
out.
REMARK
“E01“ is displayed on the character display, and then “MAINTE-
NANCE“ or the part of the machine requiring inspection, filling
of fluid, or replacement is displayed on the line.
E00: If travel speed overrun is displayed, ease the accelerator

pedal back to reduce speed.
REMARK
“E00“ is displayed on the character display, and then “OVER-
RUN PREVENTION“ and “E00“ are displayed in turn for 3 sec-
onds each.
3-10
FAILURE CODE DISPLAY
If an action code is displayed on the character display, check the failure code according to the failure code display
method given below.
When contacting your Komatsu distributor to request repairs, please inform your distributor of the failure code.
Method of displaying failure code
1. If an action code is displayed on the character display of

display portion, press the top (>) of monitor panel mode
selector switch 2 (A).
The action code will change to the failure code.

q The failure code is displayed with the first 6 digits on
the left side of the character display.
q The code displayed after the space on the right side of

the failure code indicates the controller that detected
the failure code.
q The failure code and the component causing the failure

are displayed on the character display in turn for 3 sec-
onds each.
Right code Controller detecting failure code

MON Machine monitor
HST HST controller
2. Press the top (>) of monitor panel mode selector switch 2 (A) again.
If the condition is normal, the service meter is displayed for several seconds, then the display returns to the
action code.
If more than one failure has occurred at the same time, the next failure code is displayed.
3-11
FILTER, OIL REPLACEMENT TIME DISPLAY
After completion of the system check and when the starting

switch is in the ON position, if any filter or oil item is approach-
ing the replacement time, this display (4) shows the item for
approx. 30 seconds. When this happens, the maintenance
caution lamp also flashes or lights up.
After replacing the filter or changing the oil, reset the time for
replacement. For details, see “RESET METHOD FOR FIL-
TER, OIL REPLACEMENT TIME (3-27)“.
REMARK
The ID number and item name of the item needing replacement are displayed on the character display, and then
the remaining time to replacement and the number of times of replacement are displayed in turn for 3 seconds
each.
If the replacement time has already passed, a minus (-) sign appears before the time.
After the display has been given for 30 seconds, it does not appear again until the starting switch is turned to the
ON position.
The message in the illustration above is not shown on the character display if an action code is being displayed.
If there are two or more items to be displayed, they are displayed repeatedly in turn. If there are more than 10
items, all the items are displayed once each, then the display returns to the normal display.
The display appears when there is 30 hours remaining until the filter or oil replacement time. If the replacement
time has passed, a minus (-) sign appears before the time for the first 999 hours. When more than 999 hours have
passed, the display is no longer given.
The maintenance caution lamp flashes as the replacement time approaches, and after the replacement time has
passed, it lights up.
Items for display of filter, oil replacement time
Item Replacement interval (H) Character display ID number

Engine oil 500 ENG OIL 01
Engine oil filter 500 ENG FILT 02
Fuel filter 500 FUEL FILT 03
Transfer oil 1000 TRANSF OIL 25
HST oil filter 1000 HST FILT 26
Hydraulic filter 2000 HYD FILT 04
Hydraulic oil 2000 HYD OIL 10
Axle oil 2000 AXLE OIL 15
3-12
REMARK
See the section below for details of the procedure for replacing the filter and oil.
Engine oil
“CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (4-48)“
Engine oil filter

Fuel filter
“REPLACE FUEL FILTER CARTRIDGE (4-49)“
Transfer oil
“CHANGE OIL IN TRANSFER CASE (4-51)“
HST oil filter

“REPLACE HST OIL FILTER ELEMENT (4-53)“
Hydraulic filter
“CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT (4-55)“
Hydraulic oil
Axle oil
“CHANGE AXLE OIL (4-58)“
3-13
EMERGENCY STOP ITEM 3
CAUTION
If these lamps light up and the buzzer sounds, stop operations immediately and carry out inspection and
maintenance of the applicable location.
If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the lamp
for the location of the abnormality and the central warning lamp will light up.
At the same time, “E03 CALL“ and “CHECK RIGHT NOW“ are displayed on the character display in turn, so stop
the machine immediately in a safe place, then stop the engine and carry out inspection.
(1) Brake oil pressure caution lamp (3) Battery charge circuit caution lamp
(2) Engine oil pressure caution lamp (4) Steering oil pressure caution lamp
BRAKE OIL PRESSURE CAUTION LAMP
This lamp (1) lights up when the brake oil pressure goes below
the specified value.
During checks before starting (starting switch at the ON posi-

tion, engine stopped) the lamps are lighted up, and when the
engine is started, the lamps go out.
During operation (engine running)
If the brake oil pressure goes down during operation, the brake oil pressure caution lamp and central warning
lamp light up and the alarm buzzer sounds intermittently.
3-14
If the brake oil pressure caution lamp lights up, the footbrake may not work, so keep the parking brake applied to
prevent the machine from moving.
Keep the parking brake applied to prevent the machine from moving until the brake pressure becomes normal and
the brake oil pressure caution lamp goes out.
ENGINE OIL PRESSURE CAUTION LAMP
This lamp (2) lights up to warn the operator that the engine
lubricating oil pressure has dropped.

If the engine lubricating oil pressure goes down during operation, the engine lubricating oil pressure caution lamp
and central warning lamp light up and the alarm buzzer sounds intermittently.
BATTERY CHARGE CIRCUIT CAUTION LAMP
This lamp (3) lights up when the engine is running to warn the
operator that an abnormality has occurrred in the charging cir-
cuit.

If an abnormality occurrs in the charging circuit during opera-

tion, the battery charge circuit caution lamp and central warn-
ing lamp light up and the alarm buzzer sounds intermittently.
STEERING OIL PRESSURE CAUTION LAMP
(Red)
This lamp (4) lights up to warn the operator that the steering oil
pressure has dropped.

3-15
If the steering oil pressure goes down during operation, the

steering oil pressure caution lamp and central warning lamp
light up and the alarm buzzer sounds intermittently.
CAUTION ITEMS 3
CAUTION
If these lamps light up, stop operations quickly and carry out the following action.
(1) Axle oil temperature caution lamp (4) Engine cooling water temperature caution lamp
(2) Parking brake reminder caution lamp (5) Fuel level caution lamp
(3) HST oil temperature caution lamp
AXLE OIL TEMPERATURE CAUTION LAMP
This lamp (1) lights up to warn the operator that the brake oil
temperature has risen.
During checks before starting (when the starting switch is

turned to the ON position but the engine is not started), this
monitor does not light up.
In continuous heavy-duty operations or when traveling long dis-

tances downhill where the brake is used frequently, the axle oil
temperature becomes high, so the axle oil temperature caution
3-16
lamp and central warning lamp light up and the alarm buzzer
sounds intermittently.
At the same time, “E02“ and “BRAKE OVERHEAT“ are displayed on the character display in turn, so take the fol-
lowing action.
1. Release the accelerator pedal and move the speed range selector switch down one range to reduce the travel
speed.
2. Avoid using the brake.
3. Do not keep the brake pedal depressed continuously; use the brake only intermittently.
If use of the brake is reduced for a short time in the way recommended above, the axle oil temperature will go
down and the caution lamp will go out.
PARKING BRAKE REMINDER CAUTION LAMP
This lamp (2) lights up when engine is stopped but the parking
brake is not applied.
At the same time, the central warning lamp lights up and the
alarm buzzer sounds intermittently.
When the parking brake is applied, the lamp goes out and the
buzzer stops.
HST OIL TEMPERATURE CAUTION LAMP
This lamp (3) lights up to warn the operator that the HST oil

When the HST oil temperature goes up, the HST oil tempera-
ture caution lamp and central warning lamp light up, and the
At the same time, “E02“ and “HST OVERHEAT“ are displayed

on the character display in turn, so stop the machine and run
the engine at a midrange speed under no load until the lamp
goes out.
3-17
ENGINE COOLING WATER TEMPERATURE CAUTION LAMP
cooling water temperature has risen.

If the engine cooling water temperature rises, the engine cool-

ing water temperature caution lamp only will light up.
If the water temperature rises further, the central warning lamp

will light up and the alarm buzzer will sound intermittently.
At the same time that the central warning lamp lights up, “E02“
and “ENGINE OVERHEAT“ are displayed on the character dis-
play in turn, so stop the machine and run the engine at a mid-
range speed under no load until the lamp goes out.
FUEL LEVEL CAUTION LAMP
This lamp (5) lights up if the amount of fuel remaining in the

fuel tank goes below 31 liters (8.19 US gal).
If it lights up, check and add fuel as soon as possible.
REMARK
Even if the caution lamp lights up, action code “E02“ is not dis-
played on the character display.
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED 3
When the travel speed goes above 40.0 km/h (24.9 MPH), the
central warning lamp lights up and the alarm buzzer sounds.
At the same time, “E00“ is displayed on the character display,

and then “OVERRUN PROTECT“ and “E00“ are displayed in
turn for 3 seconds each.
If the alarm buzzer sounds, ease the accelerator pedal back

and reduce speed.
TRAVEL SPEED LIMIT FUNCTION
The travel speed is automatically controlled so that it does not go above approx. 42 km/h (26.1 MPH).
3-18
INSPECTION AND MAINTENANCE ITEM 3
CAUTION
(1) Radiator water level caution lamp (4) HST oil filter clogging caution lamp
(2) Engine oil level caution lamp (5) Air cleaner clogging caution lamp
(3) Maintenance caution lamp
RADIATOR COOLANT LEVEL CAUTION LAMP
This lamp (1) lights up to warn the operator that the coolant
level in the radiator has gone down.

monitor lights up if the coolant level in the radiator is low.
At the same time, “E01“ and “COOLANT LOW“ are displayed

on the character display in turn, so check the coolant level in
the radiator sub-tank, and add coolant.
If the coolant level in the radiator becomes too low, the radiator
coolant level caution lamp will light up.
At the same time, “E01“ and “COOLANT LOW“ are displayed on the character display in turn, so stop the engine,
check the coolant level in the radiator sub-tank, and add coolant.
3-19
ENGINE OIL LEVEL CAUTION LAMP
This lamp (2) lights up to warn the operator that the oil level in
the engine oil pan has gone down.

monitor lights up if the oil level in the engine oil pan is low.
At the same time, “E01“ and “ENG OIL LEV LOW“ are dis-
played alternately on the character display, so do not start the
engine. Check the oil level in the engine oil pan and add oil.
MAINTENANCE CAUTION LAMP
CAUTION
If the caution lamp lights up, repair the problem as soon as possible. If this is left as it is, it will lead to fail-
ure.
When the time for oil change is reached, this lamp (3) flashes
or lights up for approx. 30 seconds after completion of the sys-
tem check when the starting switch is at the ON position.
REMARK
The maintenance caution lamp flashes when there is less than
30 hours to the replacement time, and after the replacement
time has passed, it stay on.
For details of the items covered by filter and oil replacement, see “FILTER, OIL REPLACEMENT TIME DISPLAY
(3-12)“.
After replacing the filter or changing the oil, reset time for the replacement. For details, see “RESET METHOD
FOR FILTER, OIL REPLACEMENT TIME (3-27)“.
HST OIL FILTER CLOGGING CAUTION LAMP
When the engine is running, this lamp (4) lights up if the HST
oil filter is clogged.

This lights up if the HST oil filter is clogged.

At the same time, “E01“ and “HST OIL FILTER“ are displayed
on the character display in turn, so replace the oil filter.
REMARK
The lamp may light up in cold temperatures, but it should go out when the HST oil temperature gauge indicator
enters the white range.
3-20
AIR CLEANER CLOGGING CAUTION LAMP
This lamp (5) lights up if the air cleaner element becomes

clogged when the engine is running.

The lamp lights up if the air cleaner element becomes clogged.

At the same time, “E01“ and “AIR FILTER“ are displayed alter-
nately on the character display, so stop the engine and clean or
replace the element.
3-21
PILOT DISPLAY PORTION 3

When the starting switch is ON, the pilot display lights up when the display items are functioning.
(1) Parking brake pilot lamp (5) Pilot lamp for speed range selector switch position
(2) Preheating pilot lamp (6) Turn signal pilot lamp
(3) Emergency steering pilot lamp (7) Head lamp high beam pilot lamp
(4) Directional lever position pilot lamp
PARKING BRAKE PILOT LAMP
This lamp (1) lights up when the parking brake is applied.
PREHEATING PILOT LAMP
This lamp (2) lights up when the engine preheating electric

heater is actuated.
In cold weather, when the starting switch is turned to the ON
position, this lamp lights up, and when the preheating is com-
pleted, it goes out.
The preheating time differs according to the engine water tem-

perature.
3-22
EMERGENCY STEERING PILOT LAMP
(Green)
If this lamp (3) lights up when the engine is running or when the
machine is operating, it indicates that the condition is normal.
If it does not light up, an abnormality has occurred in the emer-

gency steering circuit.
Move the machine immediately to a safe place, stop the

engine, and check the condition.
DIRECTIONAL LEVER POSITION PILOT LAMP
This lamp (4) indicates the position of the directional lever.
F lights up: FORWARD
N lights up: NEUTRAL
R lights up: REVERSE
PILOT LAMP FOR SPEED RANGE SELECTOR SWITCH POSITION
This lamp (5) indicates the position of the speed range selector
switch.
TURN SIGNAL PILOT LAMP
When the turn signal lamp flashes, this lamp (6) also flashes.
REMARK
If there is a disconnection in the turn signal lamp, the flashing
interval becomes shorter.
3-23
HEAD LAMP HIGH BEAM PILOT LAMP
This lamp (7) lights up when the head lamp is at high beam.
3-24
METER DISPLAY PORTION 3
(1) HST oil temperature gauge (4) Speedometer
(2) Engine cooling water temperature gauge (5) Meter display pilot lamp
(3) Fuel gauge
HST OIL TEMPERATURE GAUGE
This meter (1) indicates the HST oil temperature.

During normal operations, the indicator should be in the white
range (A).
If the indicator enters red range (B) during operations, caution

lamp (C) inside the HST oil temperature gauge lights up. At the
same time, the central warning lamp lights up and the alarm
buzzer sounds. In addition, “E02“ and “HST OVERHEAT“ are
displayed on the character display in turn.
Run the engine at a midrange speed under no load and wait for
the indicator to return to the white range (A).
ENGINE COOLING WATER TEMPERATURE GAUGE
This meter (2) indicates the engine coolant temperature.

range (A).

lamp (C) inside the engine coolant temperature gauge lights
up. At the same time, the central warning lamp lights up and
the alarm buzzer sounds. In addition, “E02“ and “ENGINE
OVERHEAT“ are displayed on the character display in turn.
Run the engine at a midrange speed under no load and wait for
the indicator to return to the white range (A).
3-25
FUEL GAUGE
This meter (3) indicates the amount of fuel remaining in the fuel
tank.
If the indicator is at the F position, it indicates that the tank is

full.
If the indicator is at the E position, it indicates that there is little

fuel remaining. When the amount of remaining fuel goes below
31 liters (8.19 US gal), caution lamp (A) inside the fuel gauge
lights up.
If it lights up, check the fuel level and add fuel.
SPEEDOMETER
This meter (4) indicates the travel speed of the machine.
METER DISPLAY PILOT LAMP
This lamp (5) displays the unit for the travel speed.
3-26
OTHER FUNCTIONS OF MACHINE MONITOR 3

The machine monitor also has the following functions.
Odometer, filter/oil replacement time reset, language selection, HST selector function
METHOD OF DISPLAYING ODOMETER
Use this when checking the total distance that the machine has traveled.
1. Check that the character display is showing the service meter or the action code. If it is giving any other dis-
play, turn the starting switch OFF, then turn the starting switch to the ON position and wait for the above dis-
play to be given.
2. Press the ( ) of monitor panel mode selector switch 1. It

displays the odometer.
3. When completing the operation, press () of monitor panel

mode selector switch 1 or turn the starting switch OFF.
RESET METHOD FOR FILTER, OIL REPLACEMENT TIME

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

and display “MAINTENANCE MONITOR“.
3. Press the ( ) of monitor mode selector switch 1.
The item is displayed, and then the replacement interval is

displayed in the center and the number of times of replace-
ment is displayed on the right in turn for 3 seconds each.
4. Press the (>) or (<) of monitor panel mode selector switch

2 to display the item (filter or oil) which has reached the
replacement time.
3-27
5. Press the ( ) of monitor mode selector switch 1.

[RESET] and [YES <> NO] are displayed in turn.
6. When resetting the replacement time, press (>) or (<) of

monitor panel mode selector switch 2, align the cursor with
“YES“, then press () of machine monitor mode selector
switch 1. It will reset and return to the previous screen.
To abort, align the cursor with “NO“, then press () of mon-
itor panel mode selector switch 1.
7. When resetting the replacement time for another item, carry out the procedure from Step 4. After completing,
press () of monitor panel mode selector switch 1 twice or turn the starting switch OFF.
METHOD FOR SELECTING LANGUAGE

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

and display “LGUAGE“.
3. Press the ( ) of monitor mode panel selector switch 1.

The presently selected language is displayed.

and select the language.
The available languages are English, Japanese, German, French, Italian, Spanish, and Swedish.
5. After selecting the language, press the ( ) of monitor mode selector switch 1. This confirms the language. To
abort, press the () of monitor mode selector switch 1.
6. When completing the operation, press () of monitor panel mode selector switch 1 twice or turn the starting
switch OFF.
3-28
METHOD OF SELECTING HST CHANGING FUNCTION
When the speed range selector switch is in 3rd or 4th position, there are two selections available for the HST. Use
this when changing the selection.
Speed range selector switch position

Function
3rd position 4th position
A (default setting) F3, R3 F4, R4
B F3, R2 F4, R2

and display “SELECT HST“.
3. Press the ( ) of monitor mode selector switch 1. The

present HST selection is displayed.
4. Press the (<) or (>) of monitor mode selector switch 2, and

align the cursor with A or B.
5. Press the () of monitor mode selector switch 1.
The HST selection is confirmed and the screen returns to

the previous screen.
switch OFF.
3-29
SWITCHES 3
(1) Starting switch (10) Hazard lamp switch

(2) Speed range selector switch (11) Front working lamp switch
(3) Variable shift control switch (12) Rear working lamp switch
(4) Directional selector switch (13) Monitor panel mode selector swiitch 1
(5) Directional selector actuation switch (14) Monitor panel mode selector swiitch 2
(6) Traction control switch (15) Front wiper switch
(7) E.C.S.S. switch (16) Rear wiper switch
(8) Lamp switch (17) Cigarette lighter
Turn signal lever (18) Room lamp switch
Dimmer switch
(19) Rear heated wire glass switch
(9) Horn button
STARTING SWITCH
This switch (1) is used to start or stop the engine.
OFF position
In this position, it is possible to insert or remove the starting
switch key. All the electric system switches are off, and the
engine will stop.
ON position
In this position, electric current flows to the charging circuit,
lamp circuit, and accessory circuit.
Keep the starting switch key at the ON position while the
engine is running.
3-30
START position
This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately
after the engine has been started. The key will return to the ON position when released.
SPEED RANGE SELECTOR SWITCH
Use this switch (2) to switch the speed range.
Use 1st and 2nd for operations, and 3rd and 4th for travel.
Position (a): 1st

Position (b): 2nd
Position (c): 3rd
Position (d): 4th
VARIABLE SHIFT CONTROL SWITCH
When the speed range is in 1st, it is possible to use this dial (3)
to set the maximum speed as desired.
Turn the dial to the right to increase the setting; turn it to the left
to decrease the setting.
The conditions for use may differ according to the condition of the road surface.
Installed tire Max. speed [km/h (MPH)]

Standard tire (20.2-25) 4.0 - 13.0 (2.5 - 8.1)
DIRECTIONAL SELECTOR SWITCH
This switch (4) is used to switch the direction of travel of the

machine between forward and reverse.
F Position: FORWARD
N Position: Neutral
R Position: REVERSE
Before operating this switch, check that the condition is as fol-

lows.
q Directional lever is at N
q Directional selector switch actuation switch is at ON

If the condition is not as above, the switch will not work.
For details, see “CHANGING DIRECTION (3-79)“.
3-31
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH
When this switch (5) is turned on, the directional selector

switch is actuated.
Position (a): ON
The directional selector switch is actuated.

Position (b): OFF
The directional selector switch is turned off.
REMARK
Turn this switch ON when the directional lever and directional
selector switch are at the neutral position. At any other posi-
tion, this switch does not work.
Even if the directional selector switch is functioning, when the
directional lever is operated, the operation of the directional
lever is given priority.
SWITCH FOR TRACTION CONTROL
The traction control is switched on by means of this switch (6).

When the traction control is on, the drive force that is trans-
ferred to the wheels is reduced in the 2nd to 4th gears.
Position (ON): ON
Position (OFF): OFF
Reduction
Drive force
Travelling speed
REMARK
Traction control is effective in preventing the tires from slipping
during light-duty operations.
3-32
E.C.S.S. SWITCH
(Option)
WARNING
q If the machine is traveling or the work equipment is raised, the moment the E.C.S.S. switch is turned
ON, the work equipment will move.
q If the E.C.S.S. system is switched on, the work equipment may move.
q Never turn the E.C.S.S. switch ON during inspection or maintenance. The work equipment will move
and this will create a dangerous situation.
q Always stop the machine and lower the work equipment to the ground before operating the E.C.S.S.
NOTICE
switch.
q When carrying out inspection and maintenance, first lower the work equipment to the ground, then
turn the E.C.S.S. switch OFF before starting the inspection and maintenance operation.
q When carrying out leveling work, turn the E.C.S.S. switch OFF.
The E.C.S.S. is a device that uses the hydraulic spring effect of an accumulator to absorb the vibration of the chas-
sis during travel and allows the machine to travel smoothly and at high speed.
This switch (7) is used to turn the E.C.S.S. ON and OFF.
Position (a): ON
The pilot lamp (A) lights up and the E.C.S.S. is
actuated.
Position (b): OFF
The E.C.S.S. is not actuated.
REMARK
The travel damper is automatically actuated when the travel speed becomes more than 6 km/h (3.7 MPH); when
the travel speed goes below 5 km/h (3.1 MPH) it is automatically disengaged (when 20.5-25 tires are used).
3-33
LAMP SWITCH
This switch (8) is used to light up the front lamps, side clear-
ance lamps, tail lamps, and instrument panel.
Position (a): OFF (Lamps go out)
Position (b): Side clearance lamps, tail lamps, and instrument

panel light up
Position (c): Head lamps light up in addition to lamps at (b)

position
REMARK
The lamp switch can be operated regardless of the position of the lever.
TURN SIGNAL LEVER
This switch (8) is used to operate the turn signal lamp.
(a) position : LEFT TURN (Push lever FORWARD.)
(b) position : OFF
(c) position : RIGHT TURN (Pull lever BACK.)
REMARK
When the lever is operated, the pilot lamp turn signal pilot lamp
also flashes.
When the steering wheel is turned back, the lever automatically
returns to its original position. If it does not return, return it
manually.
DIMMER SWITCH
This switch (8) is used to switch the head lamps between high
beam and low beam.
Position (a): Low beam
Position (b): High beam
3-34
HORN BUTTON
When the horn button (9) in the center of the steering wheel is
pressed, the horn will sound.
HAZARD LAMP SWITCH
WARNING
Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for
other machine operators.
This switch (10) is used in emergencies, such as when the

machine breaks down and has to be parked on the road.
Position (a): Direction indicator lamp and directional indicator

pilot lamp flash, and pilot lamp (A) lights up at the
same time.
Position (b): Lamps go out
FRONT WORKING LAMP SWITCH
WARNING
Always turn the working lamp off before traveling on public roads.
This switch (11) is used to light up the front working lamp.
Position (a): Working lamp and pilot lamp (A) light up

Position (b): Working lamp goes out
REMARK
If the lamp switch is not at the ON position for the side clear-
ance lamp or head lamp, the working lamp will not light up.
3-35
REAR WORKING LAMP SWITCH
WARNING
Always turn the working lamp off before traveling on public roads.
This switch (12) is used to light up the rear working lamp.

Position (a): Working lamp and pilot lamp (A) light up
Position (b): Working lamp goes out
REMARK
If the lamp switch is not at the ON position for the side clear-
ance lamp or head lamp, the working lamp will not light up.
MONITOR PANEL MODE SELECTOR SWITCH 1
This switch (13) is used to switch the function of the character

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

nal position.
The basic operation is as follows.
Position ( ): Press here to select (confirm) each mode or

operation
Position (): Press here to cancel each mode or operation
MONITOR PANEL MODE SELECTOR SWITCH 2

display.

nal position.
Position (>): Press here to go on to the next screen, or to move

the cursor forward, or to increase the number
when entering numerals
Position (<): Press here to go back to the previous screen, or to

move the cursor back, or to reduce the number
3-36
FRONT WIPER SWITCH
When rotary switch (A) of this switch (15) is turned, the front
wiper will move.
If push button (B) is pressed, washer liquid will be sprayed out

onto the front glass while the button is being pressed.
Position (a): (OFF) Stop
Position (b): (INT) Intermittent wiper
Position (c): Low-speed wiper

Position (d): High-speed wiper
REAR WIPER SWITCH
When lever (C) of this switch (16) is turned, the rear wiper will
move.
Position (a): Washer liquid is sprayed out
Position (b): OFF
Position (c): Wiper is operated
Position (d): Washer liquid is sprayed out, wiper is operated
CIGARETTE LIGHTER
This is used to light cigarettes.
After cigarette lighter (17) is pushed in, it will return to its origi-
nal position after a few seconds, then you may pull it out and
light a cigarette.
3-37
ROOM LAMP SWITCH
The switch (18) is used to turn the room lamp ON and OFF.
Position (a): OFF

Position (b): Lights up when the cab door opens
Position (c): Lights up
REMARK
The room lamp lights up even when the main switch is OFF, so
when leaving the operator's compartment, turn the switch to
position (a) (OFF) or (b).
When operating with the cab door fully open, set the switch to
position (a) (OFF).
REAR HEATED WIRE GLASS SWITCH
When this switch (19) is pressed, electric current flows through

the heated wire glass at the rear and the mist is removed from
the glass.
Position (a): ON (removes mist from glass)
Position (b): OFF
3-38
CONTROL LEVERS, PEDALS 3
(1) Directional lever (5) Brake pedal

(2) Safety lock lever (for work equipment lever) (6) Accelerator pedal
(3) Lift arm control lever (7) Parking brake lever
(4) Bucket control lever
DIRECTIONAL LEVER
This lever (1) is used to switch the direction of travel of the

When starting the engine, if the directional lever is not at the N

position, the engine will not start.
Position (a): FORWARD
Position N: NEUTRAL
Position (b): REVERSE
REMARK
When the starting switch is turned to the ON position, if the
directional lever is not at the N position, the central warning
lamp lights up and the alarm buzzer sounds intermittently.
When the directional lever is set to the N position, the central
warning lamp goes out and the alarm buzzer stops.
3-39
SAFETY LOCK LEVER (FOR WORK EQUIPMENT LEVER)
WARNING
q Before leaving the operator's seat, set the safety lock lever securely to the LOCK position. If the
safety lock lever is not at the LOCK position, and work equipment control lever is touched by mistake,
it may lead to a serious accident.
q If the safety lock lever is not placed securely at the LOCK position, the work equipment control lever
may move, and this may lead to a serious accident or personal injury. Check that the lever is in the
LOCK position.
q When operating the safety lock lever, check that the work equipment control lever is held securely at
the HOLD position.
q When pulling up or pushing down the safety lock lever, be careful not to touch work equipment control
lever.
This lever (2) is a lock device for the work equipment control
lever.
Push the safety lock lever down to lock it.
REMARK
If the safety lock lever is at the LOCK position, the work equip-
ment will not move even when the work equipment control
lever is operated.
LIFT ARM CONTROL LEVER
This lever (3) is used to operate the lift arm.
NOTICE
Do not use the FLOAT position when lowering the bucket.
Use the FLOAT position when leveling, see “LEVELING
OPERATIONS (3-89)“.
Position (a): RAISE
When the lift arm control lever is pulled further

from the RAISE position, the lever is stopped in
this position until the lift arm reaches the preset
position of the kickout, and the lever is returned to
the HOLD position.
Position (b): HOLD

The lift arm is kept in the same position.
Position (c): LOWER
Position (d): FLOAT

The lift arm moves freely under external force.
3-40
BUCKET CONTROL LEVER
This lever (4) operates the bucket.
Position (a): TILT

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

Position (c): DUMP
BRAKE PEDAL
WARNING
q When traveling downhill, always use the right brake pedal, and use the braking force of the engine
together with the brake.
q Do not use the brake pedal excessively. If the brake is used too frequently, the brake will overheat. If
this happens, the brakes will not work and may lead to a serious accident.
q Do not put your foot on the brake pedal unless necessary.
These pedals (5) operate the brakes.
Use the brake pedal for normal braking operations.
The left and right pedals are interconnected and work together.
REMARK
When using the brake pedal and accelerator pedal together to
reduce the travel speed or stop the machine when carrying out
the operation, it is more convenient to use the left brake pedal.
3-41
ACCELERATOR PEDAL
This pedal (6) controls the engine speed and output.
The engine speed can be freely controlled between low idling

and full speed.
PARKING BRAKE LEVER
WARNING
Always apply the parking brake when leaving the machine or when parking it.
q Never use the parking brake lever to brake the machine when traveling except in an emergency. The
NOTICE
parking brake may be damaged and this may lead to a serious accident. Apply the parking brake only
after the machine has stopped.
q If the parking brake has been used as an emergency brake when traveling at high speed (near the max-
imum speed), contact your Komatsu distributor to have the parking brake checked for any abnormal-
ity.
This lever (7) operates the parking brake.
Pull the lever up to the LOCK position to actuate the parking

brake. At the same time, the parking brake pilot lamp will light
up.
To release the brake, pull the lever, then press button (A) at the
tip of the lever and return the lever to the FREE position. At the
same time, the parking brake pilot lamp will go out.
REMARK
If the directional lever is placed at the FORWARD or
REVERSE position with the parking brake still applied, the
central warning lamp will light up and the buzzer will sound.
Before operating the directional lever, check that the parking
brake lever is at the FREE position.
When the parking brake is applied, the machine will not move
even if the directional lever is operated.
3-42
STEERING TILT LOCK LEVER 3
WARNING
Stop the machine before adjusting the tilt of the steering wheel. If this operation (adjustment) is carried
out while the machine is moving, it may lead to a serious accident or personal injury.
This lever allows the steering column to be tilted forward or

backward.
The amount of adjustment is 8° to the front and 10° to the rear
(stepless) from the neutral position.
1. Set the lever (1) to FREE position (a).
2. Set the steering wheel (2) to the desired position, then set
lever (1) to LOCK position (b).
CAP AND COVER WITH LOCK 3

Use the starting key to open and close the locks on the caps
and covers.
For details of the locations of the caps and covers with locks,
see “LOCKING (3-98)“.
Insert the key as far as it will go, then turn it. If the key is turned
before it is inserted fully, it may break.
METHOD OF OPENING AND CLOSING CAP WITH LOCK
(FOR THE FUEL TANK FILLER PORT)
TO OPEN THE CAP
1. Insert the key into the key slot.
2. Turn the key clockwise, align the key slot with the match
mark on the cap, then open the cap.
TO LOCK THE CAP
1. Turn the cap until tight, then insert the key into the key slot.
2. Turn the key counterclockwise and take the key out.
3-43
METHOD OF OPENING AND CLOSING COVER WITH LOCK
(ENGINE SIDE COVER)
TO OPEN THE COVER
1. Insert the key into the key slot.
2. Turn the key counterclockwise and open the cover by pull-

ing the cover grip.
TO LOCK THE COVER

1. Close the cover and insert the key into the key slot.
2. Turn the key clockwise and take the key out.
SAFETY BAR 3
WARNING
q When carrying out maintenance or transporting the machine, always set the safety bar to the LOCK
position.
q Always remove the safety bar for travel operations. If it is not removed, the steering wheel cannot be
used for steering, and this may lead to serious damage or injury.
This is a device used to lock the front and rear frames during
maintenance or when transporting the machine. It prevents the
front and rear frames from articulating.
3-44
TOWING PIN 3
1. Align protrusion (1) in the towing pin with groove (2) in the
counterweight, then insert the pin and turn it 180°.
2. To prevent the towing pin from turning, fold the handle of

the towing pin and set it in position.
Reverse this operation to remove the pin.
GREASE PUMP 3
The grease pump is stowed inside the left engine side cover at
the rear of the machine.
After using the pump, wipe off all the grease stuck to the pump,
set it in the clamp inside the cover, then fit the chain to the
clamp to prevent the pump from moving.
In addition, form the rubber ring into a figure of 8 as shown in
the diagram on the right, and secure in position.
CAB DOOR INNER LOCK 3

(Right door)
Press cab door inner lock to lock the door.
Position (a): Lock

Position (b): Release
3-45
CAB DOOR OPEN LOCK 3

When getting in or out of the operator's compartment, or when
operating with the door open, use this lock to hold the door in
position.
1. Push the door against catch (1) to lock it in position.
2. When attaching the door in position, lock it firmly to the

catch.
3. When getting on or off the machine, hold the handrail on

the inside.
4. When closing the door from the operator's seat, push knob
(2) to release the catch.
5. When closing the door after getting off the machine, pull
knob (3) to release the catch.
CAB WINDOW OPEN LOCK CANCEL KNOB 3

Use this knob when you want to move the door window glass
up or down to open or close it.
Grip lock cancel knob (1) to release the lock, and move it down
to a lower lock position. Release lock cancel knob (1).
There is 1 point for lock position (2).
FUSE 3
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.
The fuses protect the electrical equipment and wiring from

burning out.
If the fuse becomes corroded, or white powder can be seen, or

the fuse is loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.
Remove cover (1). The fuse boxes are A and B.
3-46
FUSE CAPACITY AND NAME OF CIRCUIT 3
FUSE BOX A
No. Fuse capacity Name of circuit

(1) 20A Starting switch
(2) 10A Hazard warning flashing lamp
(3) 10A HST control A
(4) 10A Parking brake A
(5) 10A Instrument panel
(6) 10A Radio A, Room lamp
Auxiliary pwe
(7) 10A
(Battery +24V)
(8) 10A Head Lamp L.H.
(9) 10A Head Lamp R.H.
(10) 10A Turn signal lamp
(11) 10A Back lamp, Stop lamp
(12) 20A HST control B
(13) 10A Work equipment positioner
(14) 10A Wiper
(15) 10A Radio B
FUSE BOX B
No. Fuse capacity Name of circuit

(1) 20A Air conditioner A
(2) 20A Air conditioner B
(3) 10A Beacon lamp (if equipped)
(4) 10A KOMTRAX
(5) 10A Load meter (if equipped)
Auxiliary pwr
(6) 20A
(Key on +24V)
(7) 10A D/C converter (if equipped)
(8) 10A Parking brake B
(9) 10A Horn
(10) 10A Side marker lamp L.H.
(11) 10A Side marker lamp R.H.
(12) 20A Front work lamp
(13) 20A Rear work lamp
(14) 10A Auxiliary
(15) 10A Auxiliary
3-47
SLOW BLOW FUSE 3

If the power does not come on when the starting switch is
turned ON, the slow blow fuse may be blown, so check and
replace it.
The slow blow fuse is beside the engine on the left side of the
machine.
1. Open the cover (1).
2. Open the cover of slow blow fuse box (2) and inspect.
For details of the method of replacing the slow blow fuse, see
Section “REPLACE SLOW BLOW FUSE (4-35)“.
SLOW BLOW FUSE
(A) 80A: Chassis power source
(B) 120A: Engine preheating power source
(C) 30A: Battery power (starting switch, hazard)
(D) 30A: Fuel solenoid power source
POWER OUTLET 3
Removing the cigarette lighter (1) allows use of its power. The
maximum electric current is 7 A (168 W).
STORAGE BOX 3
This is under the operator's seat.
Use this box to keep small items and tools.
REMARK
The storage box is not waterproof. When washing the floor,
remove all documents and other items that may be damaged
by water, and keep them in a waterproof bag.
3-48
AIR CONDITIONER 3
By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it pos-
sible to provide a pleasant working environment even on dusty jobsites.
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL 3
(1) Fan switch (4) FRESH/RECIRC switch
(2) Air conditioner switch (5) Temperature control switch
(3) Mode selector switch
FAN SWITCH
This switch (1) can be used to adjust the air flow to four stages.
It also acts as the main switch for the air conditioner. When the
OFF switch is pressed, the fan stops.
When the switch is pressed, the indicator lamp above the

switch lights up to display the air flow.
3-49
AIR CONDITIONER SWITCH
This switch (2) is used to start or stop the cooling or dehumidi-

fying function.
When the fan switch is turned ON and the air conditioner

switch is pressed, the indicator lamp above the switch lights up.
When the switch is pressed again, the switch is turned OFF
and the indicator lamp goes out.
MODE SELECTOR SWITCH
This switch (3) is used to select the vents.
The following five vent modes are available: FACE, FACE/

FOOT, FOOT, FOOT/DEF, DEF.
When the switch is pressed, the indicator lamp above the

switch lights up to display the vent mode.
FRESH/RECIRC SELECTOR SWITCH
This switch (4) is used to select between recirculation of the air

inside the cab or intake of fresh air from outside.
When the switch is pressed, indicator lamp (A) at the top of the
switch lights up.
Recirculation of air inside cab
Press this switch (B) to use only the air inside the cab. Use this position to carry out rapid heating or cooling of the
cab or when the outside air is dirty.
Intake of fresh air from outside

Press this switch (C) to carry out heating or cooling with fresh air taken in from the outside. Use this position when
fresh air is taken in from outside the cab, or when removing the mist from the cab windows.
REMARK
When fresh air is taken into the cab, air pressure in the cab increases, which prevents the dust from entering.
When neither heating nor cooling is needed, bring in clean fresh air to prevent the dust from coming in with your
preferred air flow.
3-50
TEMPERATURE CONTROL SWITCH
The temperature can be adjusted with this switch (5) by press-

ing and holding the up or down button.
The temperature level indicator lamps (A) light up to display the

temperature of the air coming from the vents.
The more blue lamps on, the lower the temperature is.
The color of the indicator lamp (A) changes while the switch is
being pressed.
When the temperature reaches the desired level, release the

switch to set the temperature.
The settings for each mode are retained in memory even when the starting switch is turned OFF.
However, in the following cases, the settings must be made again.
q When the machine has been out of use for more than 7 days
q When the battery voltage is extremely low
q When there has been abnormal interference from outside
q When the fan switch is turned OFF (the setting is not kept in memory with only the air conditioner switch)
If the air conditioner is used at the FRESH position, the inside of the cab will be pressurized and this will prevent
the entry of dust.
The higher the position of the fan switch, the more effective the pressurizing becomes.
3-51
METHOD OF OPERATION 3
Switchs
Air conditioner Temperature FRESH/RECIRC Mode selector
Fan switch
switch control switch selector switch switch
Condition of use
Rapid HI ON All blue RECIRC FACE
Cooling More than half
Normal HI-LO ON FRESH FACE
are blue
Dehumidifying, More than half
HI-LO ON FRESH FOOT
heating are red
Rapid HI OFF All red RECIRC FOOT
Heating More than half
Normal HI-LO OFF FRESH FOOT
are red
More than half
Defroster HI ON FRESH DEF
are red
Vetilation or
HI-LO OFF All blue FRESH FACE
pressurizing
When carrying out the defrosting, if the temperature control

switch is set so that all lamps are red, this will improve the per-
formance for defrosting and demisting.
Set the vent mode selector switch to the intermediate position

to give the desired condition.
With the FACE vents, it is possible to adjust the direction of the

air flow and to turn it on or off.
However, do not set to the FACE mode with the vents closed.
WHEN NOT USING THE AIR CONDITIONER REGULARLY
Run the air conditioner at cooling or dehumidification + heating for several minutes from time to time to prevent the
loss of the oil film at various parts of the compressor.
REMARK
If the temperature inside the cab is low, the air conditioner may not work. In such cases, use the recirculated air to
heat up the inside of the cab, then turn the air conditioner switch on to run the air conditioner.
3-52
COOL BOX
When the cooling is being used, this can be used for keeping
drinks and other things cool.
When the heating is being used, it can be used to keep things

warm.
When using the box, open the vent grill (1).
When not using the box, close the grill (1).
Do not use the cool box for things which smell or leak water or
break easily.
Do not use it as a holder for tools or other small objects.
PRECAUTIONS WHEN USING 3
PRECAUTIONS WHEN USING THE COOLING
q If you smoke when using the air conditioner, your eyes may start to itch or burn, therefore ventilate the cab
every so often to remove the smoke.
q When using the air conditioner for a long period of time, carry out ventilation process at least once every hour.
When using the air conditioner, it is recommended for health reasons, that it should only feel slightly cooler
(5 or 6°C lower than the outside temperature) when you enter the cab.
Therefore, to adjust the temperature to a suitable level.
HANDLING CAB WIPER 3
PREVENTING DAMAGE TO WIPER ARM BRACKET 3
NOTICE
When angling the wiper arm (1) to the front, check that the
wiper blade is hanging free.
When angling the wiper arm (1) to the front, such as when wip-
ing the glass clean, if the wiper arm (1) is angled with the wiper
blade (2) locked to the arm (the bottom of the blade is caught
on the arm), abnormal force is brought to bear on the mounting
bracket and the bracket may break.
3-53
OPERATION OPERATION
OPERATION 3
CHECK BEFORE STARTING ENGINE, ADJUST 3
WALK-AROUND CHECK 3
Before starting the engine, walk around the machine and look to the underside of chassis for anything unusual like
looseness of the bolts and nuts, leakage of fuel, oil and cooling water. Also check the condition of the work equip-
ment and the hydraulic system.
Check also for loose wiring, play, and collection of dust at places which reach high temperature.
WARNING
Remove any flammable materials from around the battery or engine muffler, turbocharger, or other high
temperature engine parts. Leakage of fuel or oil will cause the machine to catch fire. Check carefully, and
be sure to repair any abnormalities, or please contact your Komatsu distributor.
Always carry out the items in this section before starting the engine each day.
1. Check for damage, wear, play in work equipment, cylinders, linkage and hoses.
Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage or hoses. If
any abnormality is found, repair it.
2. Remove dirt and dust from around engine, battery and radiator.
Check if there is any dirt or dust accumulated around the engine or radiator. Check also if there is any flam-
mable material (dead leaves, twigs, etc.) accumulated around the battery or high temperature engine parts,
such as the engine muffler or turbocharger. Remove all such dirt or flammable material.
3. Check for coolant or oil leakage around engine.

Check that there is no oil leakage from the engine or coolant leakage from the cooling system. If any abnor-
mality is found, repair it.
4. Check for oil leakage from HST piping, transfer case, axle, hydraulic tank, hoses and joints.
Check that there is no oil leakage. If any abnormality is found, repair the leakage.
5. Check for oil leakage from brake line.
Check that there is no oil leakage. If any abnormality is found, repair the leakage.
6. Check for damage or wear to tires and loose mounting bolts.
Check for cracks or peeling of the tires and for cracks or wear to the wheels (side rim, rim base, lock ring).
Tighten any loose wheel nuts. If any abnormality is found, repair or replace the part.
If any valve caps are missing, install new caps.
3-54
OPERATION OPERATION
7. Check for damage and loose bolts on handrail and steps.

Repair any damage and tighten any loose bolts.
8. Check the fill level of the grease container of the central lubrication system (optional). Refill grease if required.
On the display of the lubrication pump, check that there is no error message. For more information, see the
chapter SPECIAL EQUIPMENT AND ATTACHMENTS "OPERATING THE CENTRAL LUBRICATION SYS-
TEM (6-63)".
9. Check for damage to gauges, lamps on instrument panel and loose bolts.
Check for damage to the panel, gauges and lamps. If any abnormality is found, replace the parts. Clean off
any dirt on the surface. Tighten any loose bolts.
10. Check for loose air cleaner mounting bolts.
Check for the loose bolts, and if loose, tighten up.
11. Check for loose battery terminals.
Tighten any loose terminal.
12. Check for damage to seat belt and mounting clamps.
WARNING
Even if there appears to be no abnormality with the seat belt, always replace it once every three years.
REMARK
The date of manufacture of the seat belt is marked on the belt
at the place indicated by the arrow in the diagram on the right.
Check that there are no loose bolts on the equipment mounting

the seat belt to the machine, and tighten if necessary.
Tightening torque: 24.5 ± 4.9 N·m (2.5 ± 0.5 kgf·m, 18.1 ± 3.6
lbft)
If the belt is damaged or fluff is starting to form, or if there is any

damage or deformation of the seat belt holders, replace the
seat belt.
13. Clean cab window.
Clean the cab window to ensure good visibility when operating the machine.
3-55
OPERATION OPERATION
14. Inspect tires.
WARNING
If worn or damaged tires are used, they may burst and
cause serious injury or death.
To ensure safety, do not use the following tires.
Wear:
Tires with a tread groove of less than 15% of that of a new
tire
Tires with extreme uneven wear or with stepped-type wear
Damage:
Tires with damage which has reached the cords, or with
cracks in the rubber
Tires with cut or pulled cords
Tires with peeled (separated) surface
Tires with damaged bead
Leaking or improperly repaired tubeless tires
Deteriorated, deformed or abnormally damaged tires
which do not seem usable
15. Inspect rims.
WARNING
Check the rims (wheels) and rings for deformation, corrosion and cracks.
In particular, check the side rings, lock rings and rim flanges thoroughly.
3-56
OPERATION OPERATION
CHECK BEFORE STARTING 3

Always carry out the items in this section before starting the engine each day.
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious
burns. Wait for the temperature to go down before starting the operation.
1. Open the engine side cover on the right side of the chassis.
2. Take out the dipstick (G) and wipe off the oil with cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.
4. The oil level should be between the H and L marks on dip-

stick (G).
If the oil level is below the L mark, add oil through oil filler
(F).
5. If the oil is above the H line, open drain valve (P), drain the
excess engine oil, then check the oil level again.
6. If the oil level is correct, tighten oil filler cap (F) securely
and close the inspection window.
REMARK
When checking the oil level after the engine has been oper-
ated, wait for at least 15 minutes after stopping the engine
before checking.
If the machine is at an angle, make it horizontal before check-
ing.
3-57
OPERATION OPERATION
CHECK WATER SEPARATOR
The water separator separates water mixed in the fuel. If float

(2) goes above water drain line (2), drain the water as follows.
1. Loosen drain plug (3) and drain the accumulated water

until the float (1) reaches the bottom.
2. Tighten drain plug (3).
3. If the air is sucked into fuel line when draining and water,
be sure to bleed air in the same manner as for the fuel fil-
ter. See “REPLACE FUEL FILTER CARTRIDGE (4-49)“.
3-58
OPERATION OPERATION
CHECK COOLANT LEVEL, ADD COOLANT
WARNING
q Do not open the radiator cap unless necessary. When checking the coolant, always wait for the
engine to cool down and check the sub tank.
q Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under
high internal pressure. If the cap is removed to check the coolant level in this condition, there is a
hazard of burns. Wait for the temperature to go down, then turn the cap slowly to release the pres-
sure before removing it.
CAUTION
When adding coolant, use the step and handrail provided, and support your body securely.
To top up coolant in the radiator, use a suitable climbing aid (for example a ladder) to climb up the back of
the machine.
1. Open top cover (1) at the front of the engine hood.
2. Check that the coolant level is between the FULL and LOW
marks on radiator sub-tank (2). If the coolant level is low,
add coolant through the coolant filler of sub-tank (2) to the
FULL level.
3. After adding coolant, tighten the cap securely.
4. If sub tank (2) is empty, check for coolant leakage, then

check the coolant level in the radiator. If the coolant level
is low, add coolant to the radiator, then add coolant to sub
tank (2).
To top up coolant in the radiator, use a suitable climbing aid

(for example a ladder) to climb up the back of the machine.
If the volume of coolant added is more than usual, check for

possible leakage.
Confirm that there is no oil in the coolant.
CHECK INFLATION PRESSURE OF TIRES
Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.
Check for damage or wear to the tires and the rims. Check for loose wheel hub nuts (bolts).
The appropriate inflation pressure differs according to the type of work, so see Section “HANDLING THE TIRES
(3-99)“ for details.
3-59
OPERATION OPERATION
CHECK ELECTRIC WIRING
CAUTION
If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask
your Komatsu distributor to locate the cause and make the repair.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged
with dirt or dust, wash the battery cap to clear the breather hole.
Check for damage and wrong capacity of the fuse and any sign of disconnection or short circuit in the electric wir-
ing. Check also for loose terminals and tighten any loose parts.
Particularly, check the wiring of the “battery“, “starting motor“ and “alternator“ carefully.
When carrying out checks around the battery, always check if there is any accumulation of flammable material
around the battery, and remove such flammable material.
Please contact your Komatsu distributor for investigation and correction.
CHECK MONITOR PANEL
1. Turn the starting switch to the ON position.
2. Check that all the monitors, gauges, and the central warn-
ing lamp light up for approx. 3 seconds and the alarm
buzzer sounds for approx. 3 sec.
If the lamps do not light up, there is probably a failure or

disconnection, so contact your Komatsu distributor for
inspection.
3-60
OPERATION OPERATION
CHECK FUEL LEVEL, ADD FUEL
WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up com-
pletely. Never bring flames near fuel because it is highly flammable and dangerous.
NOTICE
If the engine has run out of fuel and has stopped, it is necessary to operate the priming pump to bleed the
air completely from the fuel line before starting the engine again.
Take care not to let the engine stop because of lack of fuel.
If the engine has run out of fuel, the air bleeding operation can be carried out more quickly if the fuel tank
is completely filled with fuel.
1. Turn the engine starting switch to the ON position and

check the fuel level with fuel level gauge (G).
After checking, turn the switch back to the OFF position.
2. If the level is low, open rear grill (1) and add through filler
port (F) to fill the tank.
For details of the method for opening and closing the cap,
see “METHOD OF OPENING AND CLOSING CAP WITH
LOCK (3-43)“.
3. After adding fuel, tighten the cap securely.

Fuel tank capacity: 228 liters (60.24 US gal)
CHECK PARKING BRAKE

Check that the parking brake works properly.
If there is any abnormality in the operation of the parking brake or the brake does not provide the proper braking
effect, please contact your Komatsu distributor for adjustment.
3-61
OPERATION OPERATION
CHECK BRAKE PEDAL
Drive the machine forward and check the effect of the brakes.
If there is any abnormality in the actuation of the brakes, please contact your Komatsu distributor to have the
brakes adjusted.
3-62
OPERATION OPERATION
ADJUSTMENT 3
SEAT ADJUSTMENT
WARNING
When adjusting the position of the operator's seat, always set the safety lock lever to the LOCK position to
prevent any accidental contact to the control levers.
q Always adjust the operator's seat before starting each operation or when the operators change shift.
q When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal
can be fully depressed.
q When pulling up levers (2) and (3), be careful not to pull up the switch box at the front by mistake.
NOTICE
There is danger that the switch box may be damaged.
q When the left armrest is at the raised position, do not push down on the tip of the armrest with your
hand to support your weight. There is danger that the armrest mount may be damaged.
Adjustments (E), (J), and (K) use the air compressor built into the seat, so turn the engine starting switch to the ON
position when carrying out the adjustment.
(A) Fore-and-aft adjustment
Pull lever (1) up, set the seat to the desired position, then
release the lever.
Amount of adjustment: 180 mm (7.1 in)

(10 mm (0.4 in) x 18 stages)
(B) Adjusting seat angle

Move lever (2) up and apply your weight to the rear of the seat.
The seat will tilt to the rear.
Move lever (3) up and apply your weight to the front of the seat.
The seat will tilt to the front.
Amount of adjustment: 24 degrees (front and rear tilt: 3 stages

each)
(C) Adjusting height of seat
Move levers (2) and (3) up and move the seat up or down to
the desired position.
These levers are also used for adjusting the seat angle, so
adjust the seat angle to set the seat to the desired height.
3-63
OPERATION OPERATION
(D) Adjusting fore-and-aft position of seat cushion

Push in lever (4), set the seat cushion to the desired position, then release the lever.
(E) Setting seat for weight
Sit on the seat, raise your body slightly, then operate switch (5) to adjust the strength of the suspension.
Amount of adjustment: 50 - 130 kg (110 - 287 lb)(target)
When + is pressed: Suspension becomes stronger
When - is pressed: Suspension becomes weaker
(F) Adjusting reclining angle
Move lever (6) up and move the backrest to the front or rear.
Push your back against the backrest when carrying out this adjustment. If your back is not pressing against the
backrest, the backrest may suddenly spring forward.
Amount of adjustment: Front tilt: Free
Rear tilt: 40 degrees (2 degrees x 20 stages)
(G) Adjusting headrest angle (if equipped)
Rotate the headrest to the front or rear.
Amount of adjustment:
Front tilt: 13 degrees
Rear tilt: 13 degrees
(H) Adjusting headrest height (if equipped)
Move the headrest up or down.
(I) Adjusting armrest angle
Rotate the knob (7) and adjust the angle of the armrest. (Left side only)
Amount of adjustment: 73 degrees (front: 54 degrees; rear: 19 degrees)
If the arm rest is turned, it will spring up. (Both left and right sides)
3-64
OPERATION OPERATION
(J) Lumbar support
Operate switch (8) to give a suitable tension to the lower lumbar region.
Operate switch (9) to give a suitable tension to the upper lumbar region.
When + is pressed: Tension becomes stronger
When - is pressed: Tension becomes weaker
(K) Side support
Operate switch (10) to give a suitable tension to the left and right lumbar region.
When + is pressed: Tension becomes stronger
When - is pressed: Tension becomes weaker
REMOVAL AND INSTALLATION OF HEADREST
Removal
If the headrest is not needed, remove it as follows.
1. Pull up the headrest to the position where it stops.
2. From the top of the seat back, turn stopper (1) (under the
material at the top of the seat) of the headrest bar on one
side in the direction of the arrow, and pull up the headrest.
When stopper (1) is turned, it will come out of groove (2).
3. Turn stopper (1) on the other side in the direction of the

arrow, and pull up the headrest.
When both stoppers (1) come out of groove (2), the head-
rest can be removed.
Installation
1. Insert the bars into the holes in the top of the seat and push
down.
3-65
OPERATION OPERATION
ADJUST SEAT BELT
Always wear the seat belt.
WARNING
q Before fastening the seat belt, check that there is no abnormality in the belt mounting bracket or
mounting belt. If the belt is worn or damaged, replace it.
q Fasten the seat belt before starting operations.
q Always wear the seat belt during operations.
Fastening and removing belt
2. Sit on the seat, hold buckle (2) and tongue (3) with your left
and right hands, insert tongue (3) into buckle (2), then pull
the belt to check that it is securely locked.
3. When removing the belt, press the red button in buckle (2)
to free the belt.
Fasten belt along your body without kinking it. Adjust the
lengths of the belt on both the buckle and the tongue sides
so that the buckle is located at the mid-point of your body
front.
3-66
OPERATION OPERATION
ADJUST LEVER STAND
Adjust height of wrist rest
Loosen lock lever (2) and adjust the height of wrist rest (1).
REMARK
Keep button (3) pressed and operate lock lever (2) to the FREE
position. The lever can be turned in the desired direction.
ADJUST REAR VIEW MIRROR
Sit in the operator's seat and adjust the rear view mirror so that
you can see properly to the rear.
Be careful to have free visibility to the mirrors. Put no obstacles

in the view area.
3-67
OPERATION OPERATION
OPERATIONS AND CHECKS BEFORE STARTING ENGINE 3
WARNING
Before starting the engine, check that the safety lock lever is securely at the LOCK position.
If the work equipment control lever is touched by accident when starting the engine, the work equipment
may move unexpectedly and cause serious damage or personal injury.
1. Check that parking brake lever (1) is at the LOCK position.
2. Check that directional lever (2) is at the N position.
REMARK
If directional lever (2) is not set to the N position, the engine will
not start.
When directional selector switch actuation switch (3) is ON, the
engine will not start if directional lever (2) and directional selec-
tor switch (4) are not both at the N position.
3-68
OPERATION OPERATION
3. Check that the bucket is completely lowered to the ground.

If it is not completely lowered, lower the bucket to the
ground as follows.
4. Check that the work equipment control lever is at the

HOLD position, then set the safety lock lever to the FREE
position.
5. Operate the work equipment control lever to lower the

bucket to the ground.
HOLD position, then set the safety lock lever to the LOCK
position.
7. Check that safety lock lever (5) is at the LOCK position.
8. Insert the key in starting switch (6), turn the key to the ON
position, and check that the machine monitor system
works.
When the starting switch is turned to the ON position

before starting the engine, monitors, gauges, and central
warning lamp light up for approx. 3 seconds, and the alarm
buzzer sounds for approx. 1 sec.
If any monitor does not light up, there is probably a failure

or disconnection, so contact your Komatsu distributor for
inspection.
3-69
OPERATION OPERATION
STARTING ENGINE 3
NORMAL STARTING 3
WARNING
q Start the engine only after sitting down in the opera-
tor's seat.
q Do not attempt to start the engine by short-circuiting
the engine starting circuit. Such an act may cause seri-
q Check that there are no persons or obstacles in the

surrounding area, then sound the horn and start the
engine.
q Exhaust gas is toxic. When starting the engine in con-

fined spaces, be particularly careful to ensure good
ventilation.
q Do not start the engine with the accelerator pedal fully

NOTICE
depressed. There is danger that the engine parts may

be damaged.
q Do not keep the starting motor rotating continuously

for more than 20 seconds.
If the engine does not start, wait for at least 2 minutes
before trying to start the engine again.
1. Turn the key of starting switch (1) to the ON position. The

automatic preheating will start and the preheating pilot
lamp (2) will light up.
The preheating time varies according to the engine water tem-

perature when the engine is started. Engine water
Preheating time (sec)
temperature [°C (°F)]
below -30 (-22) 45
The table shown below gives a guide to preheating time. -25 (-13) 38
-20 (-4) 30
-15 (5) 23
-10 (14) 15
-5 (23) 8
0 (32) 1
above 0 (32) 0
3-70
OPERATION OPERATION
2. Depress accelerator pedal (3) lightly.
3. After the preheating pilot lamp (2) goes out, turn the key of
starting switch (1) to the START position to start the
engine.
4. After the engine starts, release the key in starting switch

(1). The key will automatically return to the ON position.
3-71
OPERATION OPERATION
STARTING IN COLD WEATHER 3
WARNING
q Start the engine only after sitting down in the opera-
tor's seat.
q Do not attempt to start the engine by short-circuiting
the engine starting circuit. Such an act may cause seri-
q Check that there are no persons or obstacles in the

surrounding area, then sound the horn and start the
engine.
q Exhaust gas is toxic. When starting the engine in con-

fined spaces, be particularly careful to ensure good
ventilation.
NOTICE
Do not start the engine with the accelerator pedal fully
depressed. There is danger that the engine parts may be
damaged.
It takes some time to start up the engine when the machine is left unused for more than half a day in the ambient
temperature of approx. -20°C (-4°F). In that case, use the engine starting switch and accelerator pedal in the fol-
lowing manner.
1. Turn the key of starting switch (1) to the ON position. The

automatic preheating will start and the preheating pilot
lamp (2) will light up.
The preheating time varies according to the engine water tem-

perature when the engine is started. Engine water
Preheating time (sec)
temperature [°C (°F)]
below -30 (-22) 45
The table shown below gives a guide to preheating time. -25 (-13) 38
-20 (-4) 30
-15 (5) 23
-10 (14) 15
-5 (23) 8
0 (32) 1
above 0 (32) 0
3-72
OPERATION OPERATION
2. Depress accelerator pedal (3).
3. When preheating pilot lamp (2) goes out, turn the key in
starting switch (1) to the START position.
Keep the key in starting switch (1) at the START position to

keep the starting motor running until the engine starts.
4. The starting motor will continue to turn and the engine will
start.
5. Method of starting engine in temperatures of approx. -20°C (-4°F).
1. Keep the engine starting motor running for the max. 20 seconds, holding the key of engine starting switch (1)
in the START position, until the engine starts up.
1. If the engine fails to start up even after running the engine starting motor for about 20 seconds, stop the engine
starting motor once (release the engine starting switch key), and try the same process again after a pause for
a minute or so.
1. If the engine still fails to start up after the second attempt, try the same process for the third time after a pause
for a minute or so.
2. When the engine has started up and the engine speed

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

fully running.
REMARK
Keep the accelerator pedal depressed after the engine starts
up, until engine warming-up run is finished. Do not step on the
pedal to the full stroke.
3-73
OPERATION OPERATION
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3
WARNING
q Emergency stop
If the operation is abnormal or any other trouble occurs, turn the key in the starting switch to the OFF
position.
q If the work equipment is operated without warming up the machine sufficiently, the response of the
work equipment to the movement of the control lever will be slow, and the work equipment may not
move as the operator desires, so always carry out the warming-up operation. Particularly in cold
areas, be sure to carry out the warming-up operation fully.
NOTICE
When the hydraulic oil temperature is low, do not carry out operations under heavy load or at high speed.
There is danger that the pump may be broken.
BREAKING-IN THE MACHINE 3
CAUTION
Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the
machine under severe conditions at the beginning can adversely affect the performance and shorten the
machine life.
Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
During breaking-in operations, follow the precautions described in this manual.
q Idle the engine for 5 minutes after starting it up.
q Avoid operation with heavy loads or at high speeds.
q Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.
3-74
OPERATION OPERATION
NORMAL OPERATION 3
After starting the engine, do not immediately start operations. First, carry out the following operations and checks.
NOTICE
Do not suddenly accelerate the engine before the warm-
ing-up operation is completed.
Do not run the engine at low idling or high idling continu-
ously for more than 20 minutes.
If it is necessary to run the engine at idling, apply a load
from time to time or run the engine at a mid-range speed.
1. Depress accelerator pedal (1) lightly and run the engine

with no load at midrange speed for about 5 minutes.
To warm up the hydraulic oil in cold areas, do as follows.
2. After completing the warming-up operation, check that the

engine rotation is smooth, then check that the work equip-
ment control lever is at the HOLD position and set safety
lock lever (2) to the FREE position.
3. Depress accelerator pedal (1) lightly and run the engine at a mid-range speed.
4. Operate bucket control lever (3) to TILT position (a) and

return it to HOLD position (b) to warm up the hydraulic oil.
The relief time at the tilt position (a) should be a maximum

of 10 seconds.
With this operation, the oil will reach the relief pressure and
this will warm up the hydraulic oil more quickly.
3-75
OPERATION OPERATION
5. After carrying out the warming-up operation, check that the

gauges and pilot lamps are normal.
If there is any abnormality, carry out maintenance or repair.
Run the engine under a light load until engine cooling

water temperature gauge (4) and HST oil temperature
gauge (5) are in the white range.
6. Check that there is no abnormal exhaust gas color, noise

or vibration. If any abnormality is found, contact your
STOPPING ENGINE 3
NOTICE
If the engine is abruptly stopped before it has cooled
down, engine life may be greatly shortened. Conse-
quently, do not abruptly stop the engine except for an
emergency.
In particular, if the engine has overheated, do not abruptly
stop it but run it at medium speed to allow it to cool gradu-
ally, then stop it.
1. Run the engine at low idling for about 5 minutes to cool

down gradually.
2. Turn the key of starting switch (1) to the OFF position to

stop the engine.
3. Remove the key from starting switch (1).
3-76
OPERATION OPERATION
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE3
WARNING
q Always remove the safety bar for travel operations. If it is not removed, the steering wheel cannot be
used for steering, and this may lead to serious damage or injury.
q When moving the machine, check that the area around the machine is safe, then sound the horn
before starting.
q Do not allow people to get near the machine.

q Clear the machine's travel path of any obstacle.
q Pay particular attention to the blind spot at the rear of the machine when traveling in reverse.
MOVING THE MACHINE 3
1. Check that caution lamp (1) is not lighted up.

HOLD position, then set safety lock lever (2) to the FREE
position.
3-77
OPERATION OPERATION
3. Operate lift arm control lever (3) to set the work equipment
to the travel posture shown in the diagram on the right.
4. Depress brake pedal (4) and turn parking brake lever (5) to
the FREE position to release the parking brake.
Keep brake pedal (4) depressed.
5. Set speed range selector switch (6) to the desired position.
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th
6. Set directional lever (7) to the desired position.

Position N: NEUTRAL
q Check that the backup alarm sounds when the direc-

tional lever is set to REVERSE. If the backup alarm
does not sound, please contact your Komatsu distribu-
tor for repairs.
7. Release brake pedal (4), then depress accelerator pedal

(8) to move the machine.
3-78
OPERATION OPERATION
CHANGING DIRECTION 3
WARNING
q When changing direction between FORWARD and
REVERSE, check that the new direction of travel is
safe. There is a blind spot behind the machine, so be
particularly careful when changing direction to travel
in reverse.
q Do not switch between FORWARD and REVERSE
when traveling at high speed.
When switching between FORWARD and REVERSE,
depress the brake to reduce the travel speed suffi-
ciently, then change the direction of travel. (Max.speed
for changing direction: 13 km/h (8.1 MPH))
There is no need to stop the machine even when switching

between FORWARD and REVERSE.
Place directional lever (1) in the desired position.
Position N: NEUTRAL
q Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does
not sound, please contact your Komatsu distributor for repairs.
USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE 3
WARNING
When the directional selector switch actuation switch (3)
is at the ON position, if the directional lever (1) is operated
to FORWARD or REVERSE, the machine will travel in for-
ward or reverse according to the operation of the direc-
tional lever, regardless of the position of the directional
selector switch (2).
Priority is given to the operation of the directional lever, so
be careful when operating.
1. Place the directional lever (1) at the N position.
3-79
OPERATION OPERATION
2. Place the directional selector switch (2) at the N position.
3. Place the directional selector switch actuation switch (3) at

the ON position (a).
4. Place the directional selector switch (2) at the F (forward)

or R (reverse) position.
REMARK
When the directional selector switch actuation switch (3) is at the ON position, if the directional lever (1) is oper-
ated to FORWARD or REVERSE, the machine will travel in forward or reverse according to the operation of the
directional lever, regardless of the position of the directional selector switch (2).
Priority is given to the operation of the directional lever.
When using directional selector switch (2) again, set directional lever (1) and directional selector switch (2) to the
N position.
3-80
OPERATION OPERATION
STOPPING THE MACHINE 3
WARNING
q Avoid stopping suddenly. Give yourself ample room
when stopping.
q Even if the parking brake lever is pulled and set to the
LOCK position, there is a danger of the machine mov-
ing until the parking brake pilot lamp lights up, so keep
the brake pedal depressed.
NOTICE
Never use the parking brake lever to brake the machine when traveling except in an emergency. Apply the
parking brake only after the machine has stopped.
1. Release accelerator pedal (1), then depress brake pedal

(2) to stop the machine.
2. Place directional lever (3) in N (neutral) position.
3. Pull parking brake lever (4) and set it to the LOCK position
to apply the parking brake.
3-81
OPERATION OPERATION
TURNING 3
WARNING
q Operating the steering wheel suddenly at high speed or operating the steering wheel on steep slopes
is dangerous. Do not operate the steering wheel in such situations.
q If the engine stops when the machine is traveling, the steering becomes heavy, so never stop the
engine while traveling.
It is particularly dangerous if the engine stops when the machine is traveling on slopes, so never let
the engine stop when traveling on slopes.
If the engine stops, stop the machine immediately at a safe place.
When traveling, use steering wheel (1) to turn the machine.

With this machine, the front frame is joined to the rear frame at
the center of the machine by the center pin. The front and rear
frames bend at this point, and the rear wheels follow in the
same track as the front wheels when turning.
Turn the steering wheel lightly to follow the machine as it turns.
NOTICE
When the steering wheel is turned fully, if it reaches the
end of its stroke, do not try to turn it further.
Check that there is a play of 50 to 100 mm (2.0 to 3.9 in) in
the steering wheel. Check also that the steering works
properly. If any abnormality is found, please contact your
Komatsu distributor for inspection.
3-82
OPERATION OPERATION
EMERGENCY STEERING 3
CAUTION
Never actuate the emergency steering except during emergencies or when checking the function.
When using the emergency steering, travel at a speed of less than 5 km/h (3.1 MPH).
Emergency steering pilot lamp (green) (2) lights up to inform

the operator that the emergency steering system is normal.
The emergency steering system is provided to enable the

machine to be steered under the following conditions.
q Traveling when there is a failure in the steering system

q Coasting with the engine stopped
REMARK
The emergency steering does not work when the machine is
stopped.
When the emergency steering system detects lack of oil pressure in the steering system, steering oil pressure cau-
tion lamp (red) (3) and central warning lamp (4) light up, and the alarm buzzer sounds intermittently.
Steering oil pressure caution lamp (red) (3) lights up to inform the operator that there is a failure in the steering
system.
If steering oil pressure caution lamp (red) (3) lights up, move the machine immediately to a safe place and stop it.
Locate the cause and do not operate the machine until it has been repaired.
REMARK
If any function of the oil pressure system is used when the engine is running at low speed, steering oil pressure
caution lamp (red) (3) may light up for a moment, but if the lamp goes out again soon, there is no problem.
When the emergency steering system detects that the oil pressure in the steering circuit has been restored, the
actuation of the emergency steering system is stopped.
3-83
OPERATION OPERATION
OPERATION OF WORK EQUIPMENT 3
WARNING
Never raise the boom with the bucket fully loaded when the machine is articulated. There is danger that
the machine may tip over.
Lift arm control lever (1) and bucket control lever (2) can be
used to operate the lift arm and bucket as follows.
LIFT ARM OPERATION
NOTICE
Position (a): RAISE

When the lift arm control lever is pulled further from the RAISE
position, the lever is stopped in this position until the lift arm
reaches the preset position of the kickout, and the lever is
returned to the HOLD position.
Raise
Position (b): HOLD
The lift arm is kept in the same position.
Position (c): LOWER

Lower
Position (d): FLOAT
AE41484B-A
3-84
OPERATION OPERATION
BUCKET OPERATION
Position (a): TILT
When the bucket control lever is pulled further from the TILT
position, the lever is stopped in this position until the bucket
reaches the preset position of the positioner, and the lever is
returned to the HOLD position.
Position (b): HOLD

The bucket is kept in the same position.
Position (c): DUMP
Tilt
Dump
AE41485B-A
3-85
OPERATION OPERATION
WORK POSSIBLE USING WHEEL LOADER 3

In addition to the following, it is possible to further increase the range of applications by using various attachments.
DIGGING OPERATIONS 3
WARNING
q Never carry out digging or scooping operations with the machine articulated. There is danger that the
machine may tip over.
q Never raise the boom with the bucket fully loaded when the machine is articulated. There is danger
that the machine may tip over.
q When the machine is traveling or the work equipment is raised, the moment that the E.C.S.S. switch
(option) is turned ON, the work equipment will move.
q If the E.C.S.S. system (option) is switched on, the work equipment may move.
NOTICE
If the tires slip, the tire life will be reduced, so do not allow the tires to slip during operation.
LOADING PILED SOIL OR BLASTED ROCK

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

bucket, stop the bucket about 30 cm (12 in) from the
ground, then lower it slowly.
REMARK
If the bucket hits the ground, the front tires will come off the
ground, and the tires will slip.
2. Shift down immediately in front of the material to be loaded. When completing the shift down, depress the
accelerator pedal at the same time and thrust the bucket into the material.
REMARK
To reduce fuel consumption, depress the accelerator pedal the minimum possible amount. If it is depressed fully,
the fuel consumption will increase, but there will be no increase in the amount loaded.
3-86
OPERATION OPERATION
3. When the material is in a stockpile,keep the cutting edge of the bucket horizontal; when loading blasted rock,
have the bucket tilting slightly down.
Be careful not to get blasted rock under the bucket. This will make the front tires come off the ground and slip.
Try to keep the load in the center of the bucket; if the load is on one side of the bucket, the load will be unbal-
anced.
q Stock pile
q Blasted rock
4. At the same time as thrusting the bucket into the material,

raise the lift arm to prevent the bucket from going in too far.
By raising the lift arm, ample traction will be produced by
the front tires.
REMARK
If the bucket is thrust too much and the lift arm stops rising or
the machine stops moving forward, release the accelerator
pedal a little. Proper operation of the accelerator pedal for
each type of the soil is effective for saving of fuel and preven-
tion of wear of the tires.
5. Check that there is enough material loaded into the bucket,

then operate the bucket control lever to tilt the bucket and
load the bucket fully.
REMARK
If the bucket edge is moved up and down while pushing in the
bucket and digging, the front tires will come off the ground and
this will cause the tires to slip.
3-87
OPERATION OPERATION
6. If there is too much material loaded in the bucket, dump

and tilt the bucket quickly to remove the excessive load.
This prevents spillage of the load during hauling.
DIGGING AND LOADING ON LEVEL GROUND

q When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the
machine forward. Always be careful not to load the bucket on one side and cause an unbalanced load.
This operation should be carried out in 1st gear.
CAUTION
Do not set the bucket facing down more than 20 degrees.
1. Set the edge of the bucket facing slightly down.
2. Drive the machine forward and operate the work equip-

ment control lever forward to cut a thin layer of the surface
each time when excavating the soil.
3. Operate the work equipment control lever slightly up and

down to reduce the resistance when driving the machine
forward.
When digging with the bucket, avoid imposing the digging

force onto only one side of the bucket.
3-88
OPERATION OPERATION
LEVELING OPERATIONS 3
q Always operate the machine in reverse when carrying

NOTICE
out leveling operations.

If it is necessary to carry out leveling operations when
traveling forward, do not set the bucket dumping angle
to more than 20 degrees.
q Turn the E.C.S.S. switch (option) OFF when carrying

out leveling operations.
1. Scoop soil into the bucket. Move the machine backward

while spreading soil from the bucket little by little.
2. Go over the spread soil with the bucket teeth touching the ground and level the ground by back-dragging.
3. Scoop some more soil into the bucket, put the lift arm control lever in FLOAT position, level the bucket at
ground level, and smooth the ground by moving backward.
PUSHING OPERATION 3
CAUTION
Never set the bucket to the DUMP position when carrying out pushing operation.
When carrying out pushing operations, set the bottom of the bucket parallel to the ground surface.
LOAD AND CARRY OPERATIONS 3
WARNING
q When carrying a load, lower the bucket to lower the
center of gravity when traveling.
q When the machine is traveling or the work equipment

is raised, the moment that the E.C.S.S. switch (option)
is turned ON, the work equipment will move.
q If the E.C.S.S. system (option) is switched on, the work
equipment may move.
The load and carry method for wheel loaders consists of a cycle of scooping -> hauling ->loading (into a hopper,
truck, etc.)
Always keep the travel path properly maintained.
When using the load and carry method, see “PRECAUTIONS FOR USING LOAD AND CARRY METHOD (3-
100)“.
3-89
OPERATION OPERATION
LOADING OPERATIONS 3
Select the method of operation which will give the minimum amount of turning and travel in order to provide the
most efficient method for the jobsite.
WARNING
q Always keep the jobsite flat, and do not operate the steering wheel suddenly or apply the brakes sud-
denly when the lift arm is raised with a loaded bucket. This is dangerous.
q Never thrust the bucket in when traveling at high speed (when loading soil or crushed rock). This is
dangerous.
q When the machine is traveling or the work equipment is raised, the moment that the E.C.S.S. switch
(option) is turned ON, the work equipment will move.
q If the E.C.S.S. system (option) is switched on, the work equipment may move.
q If the tires slip, the tire life will be reduced, so do not allow the tires to slip during operation.
NOTICE
q Avoid excessive bucket shaking.
CROSS DRIVE LOADING
Always set the wheel loader facing at a right angle to the stock-
pile. After digging in and scooping up the load, drive the
machine straight back in reverse, then bring the dump truck in
between the stock pile and the wheel loader.
This method requires the least time for loading, and is

extremely effective in reducing the cycle time.
3-90
OPERATION OPERATION
V-SHAPE LOADING
Position the dump truck so that the direction of approach of the

wheel loader is approx. 60 degrees from the direction of
approach to the stockpile. After loading the bucket, drive the
wheel loader in reverse, then turn it to face the dump truck and
travel forward to load the dump truck.
The smaller the turning angle of the wheel loader is, the more
efficient the operation becomes.
When loading a full bucket and raising it to the maximum

height, first shake the bucket to stabilize the load before raising
the bucket. This will prevent the load from spilling to the rear.
PRECAUTIONS WHEN PILING UP LOADS
When forming products into a pile, be careful not to let the rear counterweight come into contact with the ground.
Do not set the bucket to the DUMP position when piling-up loads.
3-91
OPERATION OPERATION
PRECAUTIONS FOR OPERATION 3
PERMISSIBLE WATER DEPTH 3
When working in water or on swampy ground, do not let the

water come above the bottom of the axle housing.
After finishing the operation, wash and check the lubricating
points.
IF WHEEL BRAKE DOES NOT WORK 3

If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine.
NOTICE
If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the
parking brake checked for any abnormality.
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES 3
LOWER THE CENTER OF GRAVITY WHEN TURNING.
When turning on slopes, lower the work equipment to lower the center of gravity before turning. It is dangerous to
turn the machine suddenly on slopes.
BREAKING ON DOWNHILL SLOPE
If the foot brake is used frequently when traveling downhill, the brake will overheat and may be damaged. Use the
accelerator pedal to make full use of the braking force of the engine when traveling downhill.
Use the right brake pedal for braking.

If the brakes are used excessively, the axle oil temperature caution lamp may light up and the alarm buzzer may
sound intermittently. For details of the necessary action to take, see “AXLE OIL TEMPERATURE CAUTION LAMP
(3-16)“ in EXPLANATION OF COMPONENTS.
IF ENGINE STOPS
If the engine stops on a slope, apply the parking brake immediately, and lower the work equipment to the ground
and stop the machine. Then put the directional lever in neutral position, and start the engine again.
3-92
OPERATION OPERATION
PRECAUTIONS WHEN DRIVING MACHINE
When the machine travels at high speed for a long distance, the tires become extremely hot. This causes early
wear of the tires, so it should be avoided as much as possible. If the machine must be driven for a long distance,
take the following precautions.
q Follow the regulations related to this machine, and drive carefully.
q Before driving the machine, carry out the checks before starting.
q The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface.
Contact your Komatsu distributor or tire dealer for information.
q The following is a guide to suitable tire pressures and speeds when traveling on a paved surface with standard
tires. (20.5-25-12PR)
Tire pressure
Front wheel: 0.32 MPa (3.3 kgf/cm2, 46.9 PSI)
Rear wheel: 0.27 MPa (2.8 kgf/cm2, 39.8 PSI)
Speed:14 km/h (8.7 MPH)
q Check the tire pressure before starting, when the tire is cool.
q After traveling for 1 hour, stop for 30 minutes. Check the tires and other parts for damage; also check the oil
and coolant levels.
q Always travel with the bucket empty.
q Never put “calcium chloride“ or “dry ballast“ in the tires when traveling.
3-93
OPERATION OPERATION
ADJUSTING WORK EQUIPMENT POSTURE 3
WARNING
q Stop the machine on flat ground and put blocks in
front and behind the wheels.
q Set parking brake lever to the LOCK position.
q Secure the front and rear frames with the safety bar.
q Always attach the warning tag to the work equipment

control lever.
q Do not go under the work equipment when the arm is

raised. To support the work equipment securely, use a
strong support that can withstand the weight of the
work equipment and prevent the arm coming from
down.
The boom kickout makes it possible to set the bucket so that it

automatically stops at the desired lifting height (lift arm higher
than horizontal) and the bucket positioner makes it possible to
set the bucket so that it automatically stops at the desired dig-
ging angle. The setting can be adjusted to match the working
conditions.
ADJUSTING BOOM KICKOUT 3
1. Raise the bucket to the desired height, set the lift arm con-
trol lever at HOLD, then set the safety lever to the LOCK
position and stop the engine.
2. Loosen two bolts (1), and adjust plate (2) so that the bot-
tom edge is in line with the center of the sensing surface of
proximity switch (3). Then tighten the bolts to hold the
plate in position.
3. Loosen two nuts (4) to make a clearance of 3 to 5 mm

(0.118 to 0.197 in) between plate (2) and the sensing sur-
face of proximity switch (3). Then tighten the nuts to hold
in position.
Tightening torque: 14.7 to 19.6 N·m (1.5 to 2.0 kgf·m, 10.8

to 14.5 lbft)
4. After adjusting, start the engine and operate the lift arm control lever. Check that the lever is automatically
returned to HOLD when the bucket reaches the desired height.
3-94
OPERATION OPERATION
ADJUSTING BUCKET POSITIONER 3
1. Lower the bucket to the ground, set to the desired digging

angle, return the bucket control lever at HOLD, then set the
safety lever to the LOCK position and stop the engine.
2. Loosen 2 bolts (1), adjust the position of mounting bracket

(4) of the proximity switch so that the rear tip of bar (2) is in
line with the center of the sensing surface of proximity
switch (3), then tighten bolts to hold the bracket in position.
3. Loosen 2 nuts (6), adjust so that clearance (A) between

support (5) and the sensing surface of proximity switch (3)
is 0.5 to 1.0 mm (0.020 to 0.039 in), then tighten the nuts to
hold in position.

to 14.5 lbft)
4. Loosen 2 bolts (7), adjust so that clearance (B) between

bar (2) and the sensing surface of proximity switch (3) is 3
to 5 mm (0.118 to 0.197 in), then tighten the bolts to hold in
position.
5. After adjusting, start the engine and raise the lift arm.
Operate the bucket control lever to the DUMP position,
then operate it to the TILT BACK position and check that
the lever is automatically returned to the HOLD position
when the bucket reaches the desired digging angle.
BUCKET LEVEL INDICATOR 3
(A) and (B) at the top rear of the bucket are the level indicators,
so the bucket angle can be checked during operations.
(A): Parallel with cutting edge
(B): 90 degrees to cutting edge
3-95
OPERATION OPERATION
PARKING MACHINE 3
WARNING
q Avoid stopping suddenly. Give yourself ample room
when stopping.
q Do not park the machine on slopes.
If the machine has to be parked on a slope, set it facing
directly down the slope, then dig the bucket into the
ground and put blocks under the tires to prevent the
machine from moving.
q If the control lever is touched by accident, the work

equipment or the machine may move suddenly, and
this may lead to a serious accident. Before leaving the
operator's compartment, always set the safety lock
lever securely to the LOCK position.
q Even if the parking brake lever is pulled and set to the

LOCK position, there is a danger of the machine mov-
ing until the parking brake pilot lamp lights up, so keep
the brake pedal depressed.
NOTICE
Never use the parking brake lever to brake the machine
when traveling except in an emergency. Apply the parking
brake only after the machine has stopped.
1. Release accelerator pedal (1), then depress brake pedal

(2) to stop the machine.
2. Place directional lever (3) in N (neutral) position.
3-96
OPERATION OPERATION
3. Pull parking brake lever (4) and set it to the LOCK position.
4. Operate lift arm control lever (5) to lower the bucket to the
ground.

HOLD position, then set safety lock lever (6) to the LOCK
position.
CHECK AFTER STOPPING ENGINE 3

Check the engine water temperature, engine oil pressure, HST oil temperature, and fuel level with the meters and
lamps.
If the engine has overheated, do not stop it suddenly. Run the engine at a midrange speed to allow the engine to
cool down before stopping it.
CHECKS AFTER COMPLETION OF OPERATION 3

1. Walk around the machine and check the work equipment, body work, and undercarriage, and check also for
oil and water leakage.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
4. Remove any mud affixed to the undercarriage.
3-97
OPERATION OPERATION
LOCKING 3
Always lock the following parts.
(1) Fuel filler cap
(2) Rear grill
(3) Engine side cover (2 places)

(4) Cab door (2 places)
REMARK
The starting switch key is used also for locks (1), (2), (3) and
(4).
3-98
OPERATION OPERATION
HANDLING THE TIRES 3
PRECAUTIONS WHEN HANDLING TIRES 3
CAUTION
If the following defects are found in tyres, they must be Breaker or belt
(cord layer)
replaced for safety reasons.
q Bead wire is broken or bent, or the tyre is greatly
Tread
Shoulder
q Excessive wear and the carcass ply (excluding
deformed.
breaker) is exposed for more than 1/4 of the circumfer-
q Damage to the carcass exceeds 1/3 of the tire width.

ence.
q Tyre layers are separated.

Inner liner
q Radial cracks reach the carcass. Carcass

q Deformation or damage which makes the tyre unsuit-
Side wall
able for use.
Bead
AE40786B-A
Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without
taking due care.
TIRE PRESSURE 3
Measure the tire pressure before starting operations, when the tires are cool.
If the tire inflation pressure is too low, there will be overload; if it is too high, it will cause tire cuts and shock burst.
To prevent these problems, adjust the tire inflation pressure according to the table on the next page.
Deflection ratio = H - h / H x 100
As a guideline that can be checked visibly, the deflection ratio

of the front tire (deflection/free height) is as follows.
When carrying normal load (lift arm horizontal): Approx. 15 to

25 %
When digging (rear wheels off ground): Approx. 25 to 35 %

When checking the tire inflation pressure, check also for small
scratches or peeling of the tire, for nails or pieces of metal
which may cause punctures, and for any abnormal wear.
3-99
OPERATION OPERATION
Clearing fallen stones and rocks from the operating area and maintaining the surface will extend the tire life and
give improved economy.
q For operations on normal road surfaces, rock digging operations: High end of range in air pressure chart
q Stockpile operations on soft ground: Average pressure in air pressure chart
q Operations on sand (operations not using much digging force): Low end of range in air pressure chart
If the deflection of the tire is excessive, raise the inflation pressure within the limits given in the table to give a suit-
able deflection (see deflection ratio).
Inflation pressure MPa (kgf/cm2, PSI)

Tire size
Soft ground Normal road When shipped from factory
(Pattern)
(sandy ground) Stockpile Digging Front Tire Rear Tire
0.19 - 0.32 0.19 - 0.32 0.21 - 0.34
20.5-25-12PR 0.32 0.27
(1.9 - 3.3, (1.9 - 3.3, (2.1 - 3.5,
(L2 Traction) (3.3, 46.9) (2.8, 39.8)
27.0 - 46.9) 27.0 - 46.9) 29.8 - 49.7)
0.19 - 0.32 0.19 - 0.32 0.21 - 0.34
20.5-25-12PR 0.32 0.27
(1.9 - 3.3, (1.9 - 3.3, (2.1 - 3.5,
(L3 Rock) (3.3, 46.9) (2.8, 39.8)
27.0 - 46.9) 27.0 - 46.9) 29.8 - 49.7)
Stockpile operations mean the loading of sand and other loose materials.
PRECAUTIONS FOR USING LOAD AND CARRY METHOD 3

When traveling continuously with load and carry operations, choose the correct tires to match the operating condi-
tions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged, so con-
tact your Komatsu distributor or tire dealer when selecting tires.
3-100
OPERATION TRANSPORTATION
TRANSPORTATION 3
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION PROCEDURE 3
As a basic rule, always transport the machine on a trailer.
When selecting the trailer, see the weights and dimensions given in Section “TECHNICAL DATA (5-2)“.
Note that the specifications for the weights and dimensions for transportation differ according to the type of tires
and type of bucket.
LOADING, UNLOADING WORK WITH TRAILERS 3
WARNING
q When loading or unloading the machine, run the engine at low speed, travel at low speed, and operate
slowly.
q When loading or unloading the machine, stop the trailer on firm level ground.
In addition, keep well away from the road shoulder.
q Use ramps of ample width, length, thickness, and strength, and install them securely at an angle of
less than 15°.
When using an embankment, compact the fill soil thoroughly and make sure that the slope face does
not collapse.
q Remove the mud stuck to the undercarriage to prevent the machine from slipping to the side on the
ramps.
In addition, remove any water, snow, ice, grease, or oil from the ramps.
q Never change direction on the ramps. There is danger that the machine may tip over.
If it is necessary to change direction, return to the ground surface or the trailer platform, correct the
direction, and start again.
q The position of the center of gravity of the machine will change suddenly at the connection of the
ramp and trailer, and there is danger of the machine losing its balance. Always drive slowly over this
point.
When loading or unloading, always use ramps or a platform and carry out the operation as follows.
LOADING 3
1. Load and unload on firm level ground only.
Maintain a safe distance from the edge of a road.
3-101
TRANSPORTATION OPERATION
2. Apply the brakes on the trailer securely and insert blocks

under the tires to ensure that the trailer does not move.
Then fix the ramps in line with the centers of the trailer and
the machine.
Ramp
Be sure that the two sides are at the same height as one
another.
Make the angle of the ramps a maximum of 15º. Blocks

Distance
Block
Set the distance between the ramps to match the center of between ramps 9ER01312A
the tires.
If the ramp sags appreciably, reinforce it with blocks, etc.
3. Determine the direction of the ramp, then slowly load the

machine.
4. Load the machine correctly in the specified position on the

trailer.
SECURING MACHINE 3
Load the machine on to a trailer as follows.
1. Lower the work equipment slowly.

position.
3. Turn the starting switch to the OFF position to stop the

engine, and pull out the starting switch key.
4. Lock front frame and rear frame with safety bar.
5. Put blocks in front and behind the wheels, and secure the
machine with chains or wire rope to prevent the machine
from moving during transportation.
In particular, attach the machine securely to prevent it from

slipping sideways.
6. Always retract the car radio antenna fully.
3-102
UNLOADING 3
1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road.
2. Apply the brakes on the trailer securely and insert blocks

under the tires to ensure that the trailer does not move.
Then fix the ramps in line with the centers of the trailer and
the machine.
Ramp
Be sure that the two sides are at the same height as one
another.
Make the angle of the ramps a maximum of 15º. Blocks

Distance
Block
Set the distance between the ramps to match the center of between ramps 9ER01312A
the tires.
If the ramp sags appreciably, reinforce it with blocks, etc.
3. Remove the chains and wire ropes fastening the machine.
4. Start the engine.
Warm the engine up fully.

HOLD position, then set the safety lock lever to the FREE
position.
6. Determine the direction of the ramps, then drive the

machine slowly down the ramps to unload the machine.
3-103
LIFTING MACHINE 3
WARNING
q When lifting the machine, if the wire rope is not fitted correctly the machine may fall and cause serious
injury or even death. Raise the machine 100 to 200 mm (3.9 to 7.9 in) from the ground, check that the
machine is horizontal and that there is no slack in the wire rope, then continue to lift the machine.
q Before lifting the machine, always stop the engine and lock the brakes. Lock front frame and rear
frame with safety bar.
Lifting operations using a crane must be carried out by a qualified operator.
q Never raise the machine with any worker on it.
q Always make sure that the wire rope used for lifting the machine is of ample strength for the weight of
the machine.
q Never try to lift the machine at any position or in any posture other than the posture specified.
q Never go under the machine when it is raised.
CAUTION
When the machine is raised, check that there is no oil leakage from the hydraulic circuits.
When carrying out the lifting operation, please contact your Komatsu distributor.
NOTICE
The lifting procedure applies to machines with standard specifications.
The method of lifting differs according to the attachments and options actually installed. In such cases,
please contact your Komatsu distributor for information.
For details of the weight, see “WEIGHT TABLE (3-105)“
3-104
LOCATION OF LIFTING POSITION MARK 3
Lifting hooks (A) are located at 4 places on the machine as

shown in the diagram on the right.
Use only these 4 places when lifting; do not use any other
places. There is a serious danger that the machine will lose its
balance.
WEIGHT TABLE 3
Machine weight Front wheel load Rear wheel load Center of gravity
WA320-5H 13660 kg (30120 lb) 6060 kg (13362 lb) 7600 kg (16758 lb) 1690 mm (5 ft 7 in)
3-105
LIFTING PROCEDURE 3
CAUTION
When the machine is raised, check that there is no oil leakage from the hydraulic circuits.
When carrying out the lifting operation, please contact your Komatsu distributor.
Lifting work can be carried out only for machines with lifting marks. Before starting the lifting operation, stop the
machine in a horizontal place and do as follows.
1. Start the engine, make sure that the machine is horizontal,

then set the work equipment to the travel posture.
For details, see “MOVING THE MACHINE (3-77)“.

position.
3. Stop the engine, check that the area around the operator's
compartment is safe, then lock with the safety bar so that
the front frame and rear frame do not articulate.
4. Fit the lifting equipment to the lifting hooks (marked by the

lifting mark) at the front of the front frame and the rear of
the rear frame.
For machines equipped with a rear full fender, remove the

rear full fender before carrying out the operation.
5. When the machine leaves the ground, stop for a moment

and wait for the machine to stabilize, then continue the lift-
ing operation slowly.
3-106
OPERATION COLD WEATHER OPERATION
COLD WEATHER OPERATION 3
PRECAUTIONS FOR LOW TEMPERATURE 3

If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as fol-
lows.
FUEL AND LUBRICANTS 3

Change to fuel and oil with low viscosity for all components. For details of the specified visicosity, see “FUEL,
COOLANT AND LUBRICANTS (4-9)“.
COOLANT 3
WARNING
q Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your
eyes or on your skin, wash it off with large amount of fresh water and see a doctor at once.
q When changing the coolant or when handling coolant containing antifreeze that has been drained
when repairing the radiator, please contact your Komatsu distributor. Antifreeze is toxic, so do not let
it flow into drainage ditches or spray it on to the ground surface.
q Antifreeze is flammable, so do not bring any flame close. Do not smoke when handling antifreeze.
q Never use methanol, ethanol or propanol based antifreeze.

NOTICE
q Avoid using any leak-preventing agent, regardless if it is sold separately or in antifreeze.
q Do not mix one antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant, see “CLEAN INSIDE OF COOLING SYSTEM (4-
23)“.
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the stan-
dard requirements as shown below. With permanent antifreeze, no change of coolant is required for a year. If it is
doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for infor-
mation.
Standard requirements for permanent antifreeze

q SAE J1034
q FEDERAL STANDARD O-A-548D
REMARK
In areas where permanent antifreeze is not available, it is possible to use antifreeze whose main component is
ethylene glycol and does not contain any corrosion inhibitor. (Such antifreeze can be used for the winter season
only.) However, in such a case, the cooling water must be changed twice a year (spring and fall), so use perma-
nent antifreeze when possible.
3-107
COLD WEATHER OPERATION OPERATION
BATTERY 3
WARNING
q The battery generates flammable gas, so do not bring fire or sparks near the battery.
q Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount
of water and consult a doctor.
q Battery electrolyte dissolves paint. If it gets on to the bodywork, wash it off immediately with water.
q If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source. There is danger that the battery may explode.
q Battery electrolyte is toxic, so do not let it flow into drainage ditches or spray it on to the ground sur-
face.
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low,
the battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%, and insulate it
against cold temperature so that the machine can be started easily the next morning.
REMARK
Measure the specific gravity and calculate the rate of charge from the following conversion table.
Temperature
(°C)
20 0 -10 -20
Charging
Rate(%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
q As the battery capacity drops markedly in low temperatures, cover the battery or remove it from the machine,
keep it in a warm place, and install it again the next morning.
q If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add the water
after the day's work so as to prevent fluid in the battery from freezing in the night.
PRECAUTIONS AFTER COMPLETION OF WORK 3

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, always observe the following precautions.
q Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rod clean to
prevent damage to the seal caused by mud or dirt on the rod surface getting inside the seal together with
drops of water.
q Park the machine on hard, dry ground.

If this is impossible, park the machine on wooden boards.
The boards help protect the wheels from being frozen in soil and the machine can start next morning.
q Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
3-108
OPERATION COLD WEATHER OPERATION
AFTER COLD WEATHER 3

When season changes and the weather becomes warmer, do as follows.
q Replace the fuel and oil for all parts with oil of the viscosity specified.
For details, see “FUEL, COOLANT AND LUBRICANTS (4-9)“.
q If for any reason permanent antifreeze cannot be used, and an ethyl glycol base antifreeze (winter, one sea-
son type) is used instead, or if no antifreeze is used, drain the cooling system completely, then clean out the
inside of the cooling system thoroughly, and fill with fresh soft water.
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD

WEATHER 3
WARNING
If the steering wheel is operated and stopped while the oil
temperature is low, there may be a time lag before the
machine stops turninig.
In this case, use the safety bar to ensure safety, and per-
form the warm-up operation in a wide place.
Do not load up the hydraulic oil in the circuit continuously
for more than 5 seconds.
When the temperature is low, do not start the operation of the machine immediately after starting the engine.
Warming up steering hydraulic circuit
Slowly operate the steering wheel to the left and right to warm up the oil in the steering valve. (Repeat this opera-
tion for about 10 minutes to warm up the oil.)
NOTICE
Operate the steering wheel a little and stop in that position. Then, confirm that the machine is steered by
an angle equivalent to the turning angle of the steering wheel.
3-109
LONG-TERM STORAGE OPERATION
LONG-TERM STORAGE 3
BEFORE STORAGE 3
When putting the machine in storage for a long time, do as follows.
q Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select
level ground and cover the machine with a sheet.
q Completely fill the fuel tank, lubricate and change the oil before storage.
q Apply a thin coat of grease to the metal surface of the hydraulic piston rods.
q Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it sepa-
rately.
q Make sure that the machine does not move by setting the safety lock lever in the LOCK position.
DURING STORAGE 3
WARNING
If it is unavoidably necessary to carry out the rust-preventive operation while the machine is indoors,
open the doors and windows to improve ventilation and prevent gas poisoning.
q During storage, always operate the machine once a month so that a new film of oil will be coated over mov-
able parts and component surfaces. At the same time, also charge the battery.
q When operating the work equipment, wipe off all the grease from the hydraulic cylinder rod.
q If the machine is equipped with an air conditioner, operate it for 3 to 5 minutes once a month to lubricate each
portion of its compressor. Be sure to idle the engine at low speed for this purpose. Also, check the quantity of
refrigerant twice a year.
AFTER STORAGE 3
NOTICE
If the machine is to be used when the monthly rust prevention operation has not been carried out, please
contact your Komatsu distributor.
When using the machine after long-term storage, do as follows before using it.
q Wipe off the grease from the hydraulic cylinder rods.
q Add oil and grease to all places.
q When a machine is stored for a long period, moisture in the air will get into the oil. Check the oil before and
after starting the engine. If there is water in the oil, change the oil.
3-110
OPERATION TROUBLESHOOTING
TROUBLESHOOTING 3
WHEN MACHINE RUNS OUT OF FUEL 3
WARNING
When starting the engine again, check carefully that the area around the engine is safe before cranking
the engine.
When starting the engine after running out of fuel, fill with fuel and bleed the air from the fuel system before start-
ing.
For details of bleeding the air, see “REPLACE FUEL FILTER CARTRIDGE (4-49)“.
TOWING THE MACHINE 3
WARNING
q Check that the wire rope is of ample strength for the weight of the machine being towed.
q Do not apply a load to the wire rope suddenly.
q If there is a failure in the brake line, the brakes cannot be used, so be extremely careful when towing.
q Towing is for moving the machine to a place where inspection and maintenance can be carried out,
NOTICE
and not for moving it long distances.

The machine must not be towed for long distances.
q For details of the procedure for towing a machine when it has broken down, please contact your
This machine must not be towed except in emergencies. When towing the machine, take the following precau-
tions.
q Before releasing the brakes, put blocks under the wheels to prevent the machine from moving. If the wheels
are not blocked, the machine may suddenly move.
q When towing a machine, tow it at a low speed of less than 2 km/h (1.2 MPH), and for a distance of a few
meters to a place where repairs can be carried out. The machine should be towed only in emergencies. If the
machine must be moved long distances, use a transporter.
q To protect the operator if the towing rope or bar should break, install a protector plate to the machine being
towed.
q If it is impossible to operate the steering and brakes of the machine being towed, do not let anyone ride on the
machine.
q Check that the tow rope or bar is of ample strength for the weight of the machine being towed. If the machine
being towed must travel through mud or up hills, use a tow rope or bar of a strength of at least 1.5 times the
weight of the machine being towed.
q Keep the angle of the tow rope as small as possible. Keep the angle between the center lines of the two
machines to within 30 degrees.
3-111
TROUBLESHOOTING OPERATION
q If the machine is moved suddenly, the tow rope or bar will be subjected to an excessive load, and it may break.
Start the machine gradually and travel at a constant speed.
q The towing machine should normally be of the same class as the machine being towed. Check that the towing
machine has ample braking power, weight, and rimpull to allow it to control both machines on slopes or on the
tow road.
q When towing a machine downhill, use a larger machine for towing to provide ample rimpull and braking power,
or connect another machine to the rear of the machine being towed. This way it is possible to prevent the
machine from losing control and turning over.
q Towing may be carried out under various differing conditions, so it is impossible to determine beforehand the
requirements for towing. Towing on flat horizontal roads will require the minimum rimpull, while towing on
slopes or on uneven road surfaces will require the maximum rimpull.
WHEN ENGINE CAN BE USED 3

q 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.
q The operator should sit on the machine being towed and operate the steering in the direction that the machine
is towed.
WHEN ENGINE CANNOT BE USED 3

When towing a machine with the engine stopped, use the following procedure.
1. The transfer oil does not lubricate the system, so remove the front and rear drive shafts. If necessary, block
the tires to prevent the machine from moving.
2. The steering cannot be operated, so remove the steering cylinder.
Even if the brakes are in good condition, the brakes can only be used a limited number of times. There is no
change in the operating force for the brake pedal, but the braking force is reduced each time the pedal is
depressed.
3. Connect the towing equipment securely. When carrying out towing operations, use two machines of at least
the same class as the machine being towed. Connect one machine each to the front and rear of the machine
being towed, then remove the blocks from the tires and tow the machine.
3-112
IF BATTERY IS DISCHARGED 3
WARNING
q When checking or handling the battery, stop the
engine and turn the starting switch key to the OFF
position.
q The battery generates hydrogen gas, so there is a haz-

ard of explosion. Do not bring lighted cigarettes near
the battery, or do anything that will cause sparks.
q Battery electrolyte is dilute sulphuric acid, and it will

attack your clothes and skin. If it gets on your clothes
or on your skin, immediately wash it off with a large
amount of water. If it gets in your eyes, wash it out with
fresh water and consult a doctor.
q When handling batteries, always wear protective gog-

gles and rubber gloves.
q When removing the battery, first disconnect the cable

from the ground (normally the negative (-) terminal).
When installing, install the positive (+) terminal first.
If a tool touches the positive terminal and the chassis,
there is danger that it will cause a spark, so be
extremely careful.
q If the terminals are loose, there is danger that the

defective contact may generate sparks that will cause
an explosion.
q When removing or installing the terminals, check

which is the positive (+) terminal and which is the neg-
ative (-) terminal.
REMOVAL AND INSTALLATION OF BATTERY 3

1. Before removing battery, remove the ground cable (normally connected to the negetive (-) terminal). If any tool
touches between the positive terminal and the chassis, there is danger of sparks being generated. Loosen the
terminal and remove the wires from the battery.
2. After installing the battery, fix it with the battery fitting securely.
Tightening torque: 5.9 to 9.8 N·m
(0.6 to 1.0 kgf·m, 4.3 to 7.2 lbft)
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: 5.9 to 9.8 N·m

(0.6 to 1.0 kgf·m, 4.3 to 7.2 lbft)
REMARK
The batteries are on both sides at the rear of the machine. The battery used for the ground is on the right side of
the machine.
3-113
PRECAUTIONS FOR CHARGING BATTERY 3
When charging the battery, if the battery is not handled cor-

rectly, there is danger that the battery may explode. Always
follow the instructions in “BATTERY (3-108)“ and the instruc-
tion manual accompanying the charger, and do as follows.
q Do not use or charge the battery if the battery electrolyte

level is below the LOWER LEVEL line. This may cause an
explosion. Always check the battery electrolyte level peri-
odically and add distilled water to bring the electrolyte level
to the UPPER LEVEL line.
q Set the voltage of the charger to match the voltage of the

battery to be charged. If the voltage is not selected cor-
rectly, the charger may overheat and cause an explosion.
q 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 negative (-) terminal of the battery. Be sure to fix the clips
securely.
q Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging,
set it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire
and explode.
q If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery electrolyte and cause the battery to explode.
3-114
STARTING ENGINE WITH BOOSTER CABLE 3

When starting the engine with a booster cable, do as follows:
PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE
WARNING
q When connecting the cables, never contact the posi-
tive (+) and negative (-) terminals.
q When starting the engine with a booster cable, always
wear safety glasses and rubber gloves.
q Be careful not to let the normal machine and problem

machine contact each other. This prevents sparks from
generating near the battery which could ignite the
hydrogen gas given off by the battery.
q Make sure that there is no mistake in the booster cable

connections. The final connection is to the engine
block of the problem machine, but sparks will be gen-
erated when this is done, so connect to a place as far
as possible from the battery.
q When disconnecting the booster cable, take care not

to bring the clips in contact with each other or with the
machine body.
q The size of the booster cable and clip should be suitable for the battery size.
NOTICE
q The battery of the normal machine must be the same capacity as that of the engine to be started.
q Check the cables and clips for damage or corrosion.
q Make sure that the cables and clips are firmly connected.
q Check that the safety lock levers and parking brake levers of both machines are in the LOCK position.
q Check that each lever is in the NEUTRAL position.
CONNECTING THE BOOSTER CABLE
Keep the starting switch of the normal machine and problem machine at the OFF position.
Connect the booster cable as follows, in the order of the numbers marked in the diagram.
1. Connect one clip of booster cable (A) to the positive (+) ter-
minal of the problem machine.
2. Connect the other clip of booster cable (A) to the positive
(+) terminal of the normal machine.
3. Connect one clip of booster cable (B) to the negative (-)

terminal of the normal machine.
4. Connect the other clip of booster cable (B) to the engine

block of the problem machine.
3-115
STARTING ENGINE
WARNING
Always check that the safety lock lever is set to the LOCK position, regardless of whether the machine is
working normally or has failed. Check also that all the control levers are at the HOLD or neutral position.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start the engine of the normal machine and keep it to run at high idling speed.
3. Turn the starting switch of the problem machine to the START position and start the engine.
If the engine doesn't start at first, wait for at least 2 minutes before trying again.
DISCONNECTING THE BOOSTER CABLE
After the engine has started, disconnect the booster cables in the reverse of the order in which they were con-
nected.
1. Remove one clip of booster cable (B) from the engine

block of the problem machine.
2. Remove the other clip of booster cable (B) from the nega-
tive (-) terminal of the normal machine.
3. Remove one clip of booster cable (A) from the positive (+)
terminal of the normal machine.
4. Remove the other clip of booster cable (A) from the posi-
tive (+) terminal of the problem machine.
3-116
OTHER TROUBLE 3
ELECTRICAL SYSTEM 3
q ( ): Always contact your Komatsu distributor when dealing with these items.
q In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for
repairs.
Problem Main causes Remedy

Lamp does not glow brightly even •Defective wiring (•Check, repair loose terminals,
when the engine runs at high speed disconnections)
Lamp flickers while engine is run- •Defective adjustment of belt ten- •Check, Adjust fan belt tension
ning sion For details, see EVERY 1000
HOURS SERVICE
Even when the engine is rotating, •Defective alternator (•Replace)
the charge caution pilot lamp does •Defective wiring (•Check, repair)
not go out •Defective adjustment of fan belt •Check, Adjust fan belt tension
tension For details, see EVERY 1000
HOURS SERVICE
Abnormal noise is generated from •Defective alternator (•Replace)
alternator
Starting motor does not turn when •Defective wiring (•Check, repair)
starting switch is turned to START •Insufficient battery charge •Charge
•Defective starting motor (•Check, repair)
Pinion of starting motor keeps going •Insufficient battery charge •Charge
in and out
Starting motor turns engine slug- •Insufficient battery charge •Charge
gishly •Defective starting motor (•Replace)
Starting motor disengages before •Defective wiring (•Check, repair)
engine starts •Insufficient battery charge •Charge
Preheating pilot lamp does not light (•Check, repair)
•Defective wiring
up (•Replace)
•Defective heater relay, preheating
water temperature sensor
•Defective preheating pilot lamp
(•Replace)
Even when engine is stopped, •Defective wiring (•Check, repair)
charge caution pilot lamp does not •Defective monitor (•Replace)
light up (starting switch at ON posi-
tion)
Even when engine is stopped, •Defective pilot lamp (•Replace)
engine oil pressure caution pilot •Defective pilot lamp switch (•Replace)
lamp does not light up (starting •Defective monitor (•Replace)
switch at ON position)
3-117
CHASSIS 3
repairs.

HST
Engine is running but machine •Parking brake is applied •Release parking brake
does not move •Directional lever is not shifted prop- •Shift lever properly
erly
•No electricity is flowing to directional •Check fuse and wiring harness
lever (electrical type) connector
•Lack of oil in hydraulic tank •Add oil to specified level. See
EVERY 100 HOURS
Even when engine is run at full •Lack of oil in hydraulic tank •Add oil to specified level. See
throttle, machine only moves EVERY 100 HOURS
slowly and lacks power •Hydraulic oil temperature is low •Carry out warming-up operation
Oil overheats •Too much oil or too little oil •Add or drain oil to specified level.
See EVERY 100 HOURS
•Clogged oil cooler core •Clean oil cooler core
Noise generated •Lack of transfer oil •Add oil to specified level. See
WHEN REQUIRED
Axle
Noise generated •Lack of oil •Add oil to specified level. See
WHEN REQUIRED
•Improper oil used (for machines with •Change to specified oil
limited-slip differential)
Brake
Brake is not applied when pedal is •Disc has reached wear limit (•Replace disc)
depressed •Defective hydraulic system
· Lack of oil •Add oil to specified level. See
EVERY 100 HOURS
· Air in brake line •Bleed air. See WHEN
REQUIRED
Brake drags or not applied (•Check, repair)
•Defective adjustment of brake pedal
(•Replace)
linkage
•Clean
•Vent hole of brake valve is clogged
Brakes squeal •Disc is worn (•Replace disc)

•Large amount of water in axle oil •Change axle oil
•Deteriorated axle oil due to over-use •Change axle oil
of brake
Parking brake
Poor braking effect •Linkage is loose •Adjust
•Disc is worn (•Replace disc)
Steering
•Defective hydraulic system •Add oil to specified level. See
Steering wheel is heavy
•Lack of oil EVERY 100 HOURS
There is play in steering wheel •Steering cylinder pin is loose •Grease bearing. Or replace pin
and bushing where there is play
•Defective hydraulic system •Add oil to specified level. See
· Lack of oil EVERY 100 HOURS
3-118

Hydraulic system
Bucket lacks lifting power •Lack of oil •Add oil to specified level. See
EVERY 100 HOURS
Bucket takes time to go up •Clogged hydraulic filter •Replace cartridge, see EVERY
2000 HOURS SERVICE
Excessive bubbles in oil •Replace with good quality oil
•Poor quality oil
•Add oil to specified level. See
•Lack of oil
EVERY 100 HOURS
•Bleed air. See EVERY 2000
•Air entering oil line
HOURS
Lack of oil pressure •Lack of oil causes pump to suck in •See EVERY 100 HOURS
air SERVICE for details of adding
oil, then see EVERY 2000
HOURS SERVICE for details o
bleeding air
Irregular movement of cylinder •Lack of oil •Add oil to specified level. See
EVERY 100 HOURS
3-119
ENGINE 3
repairs.

Engine oil pressure caution pilot •Add oil to specified level, see
•Low engine oil pan oil level (suck-
lamp lights up CHECK BEFORE STARTING
ing in air)
•Replace cartridge, see EVERY
•Clogged oil filter cartridge
500 HOURS SERVICE
(•Check, repair)
•Defective tightening of oil pipe joint,
oil leakage from damaged part
•Defective monitor
(•Replace)
Steam is emitted from top part of •Check, add cooling water, repair,
•Low cooling water level, leakage of
radiator (pressure valve) see WHEN REQUIRED
water
Water temperature gauge is in red (•Check, repair)
•Defective fan pump motor
range •Change cooling water, clean
•Dirt or scale accumulated in cool-
Coolant temperature monitor lights inside of cooling system, see
ing system
up WHEN REQUIRED
•Clean or repair, see WHEN
•Clogged radiator fin or damaged fin
REQUIRED
•Defective thermostat
(•Replace thermostat)
•Loose radiator filler cap (high alti-
•Tighten cap or replace packing
tude operation)
•Defective monitor
(•Replace)
Water temperature gauge is in white •Defective thermostat (•Replace thermostat)
range on left •Defective monitor (•Replace)
Engine does not start when starting •Add fuel, see CHECK BEFORE
•Lack of fuel
motor is turned STARTING
•Repair place where air is sucked
•Air in fuel system
in
•Fuel filter with fuel. See EVERY
•No fuel in fuel filter
500 HOURS SERVICE
(•Replace pump or nozzle)
•Defective injection pump or nozzle
•Starting motor cranks engine too
•See ELECTRICAL SYSTEM
slowly
•Starting motor does not turn
•Preheating pilot lamp does not light
up
•Defective valve clearance (Defec-
(•Adjust valve clearance)
tive compression)
Exhaust gas is white or blue •Too much oil in oil pan •Add oil to specified level, see
CHECK BEFORE STARTING
•Improper fuel •Change to specified fuel
Exhaust gas occasionally turns •Clogged air cleaner element •Clean or replace, see WHEN
black REQUIRED
•Defective nozzle (•Replace nozzle)
•Defective compression (•See defective compression
above)
•Defective turbocharger (•Wash turbocharger or replace)
Combustion noise occasionally •Defective nozzle (•Replace nozzle)
makes breathing sound
3-120

Abnormal noise generated (com- •Low grade fuel being used •Change to specified fuel
bustion or mechanical) •Overheating •Refer to “Water temperature
gauge is in red range“ as above
•Damage inside muffler (•Replace muffler)
•Excessive valve clearance (•Adjust valve clearance)
3-121
3-122
MAINTENANCE
14
GUIDES TO MAINTENANCE MAINTENANCE
GUIDES TO MAINTENANCE 4
Do not carry out any inspection and maintenance operation that is not found in this manual.
CHECK SERVICE METER:

Check the service meter reading every day to see if the time has come for any necessary maintenance to be car-
ried out.
KOMATSU GENUINE REPLACEMENT PARTS:

Use Komatsu genuine parts specified in the Parts Book as replacement parts.
KOMATSU GENUINE OILS:

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem-
perature.
ALWAYS USE CLEAN WASHER FLUID:

Use automobile window washer fluid, and be careful not to let any dirt get into it.
ALWAYS USE CLEAN OIL AND GREASE:

Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from
oil and grease.
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS:

After oil is changed or filters are replaced, 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 carry out
suitable action.
FUEL STRAINER:
Do not remove the strainer from the filler port when adding fuel.
WELDING INSTRUCTIONS:
q Turn off the engine starting switch.
q Do not apply more than 200V continuously.
q Connect grounding cable within 1m (3.3 ft) from the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may malfunction.
q If a seal or bearing happen to come between the welding part and grounding point, change the grounding
point to avoid such parts.
q Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
DO NOT DROP THINGS INSIDE MACHINE:
q When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop
nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it will cause damage and malfunction of the machine, and will
lead to failure. If you drop anything inside the machine, always remove it immediately.
q Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
4-2
MAINTENANCE GUIDES TO MAINTENANCE
DUSTY WORKSITES:
When working at dusty worksites, do as follows:

q Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged.
q Clean the radiator core frequently to avoid clogging.
q Clean and replace the fuel filter frequently.
q Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
q When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from get-
ting into the oil.
AVOID MIXING OIL:
If a different type of oil has to be added, drain the old oil and replace all the oil with the new type of oil. Never mix
different kinds of oil.
LOCKING INSPECTION COVERS:
Lock inspection cover in position securely with the lock bar. If inspection or maintenance is carried out with the
inspection cover not locked in position, there is a hazard that it may be suddenly blown shut by the wind and cause
injury to the worker.
BLEEDING AIR FROM HYDRAULIC CIRCUIT:
If the hydraulic oil equipments have been repaired or replaced and if the hydraulic hoses, pipes, etc. have been
disconnected, it is necessary to bleed air in the circuit. See “CHANGE OIL IN HYDRAULIC TANK, REPLACE
HYDRAULIC FILTER ELEMENT (4-55)“.
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES:
q When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace with new parts.
When doing this, be careful not to forget to assemble the O-rings and gaskets.
q When installing the hoses, do not twist them or bend them into loops with a small radius.
This will cause damage to the hose and markedly reduce its service life.
CHECKS AFTER INSPECTION AND MAINTENANCE:
If you forget carrying out the checks after inspection and maintenance, unexpected problems may occur, and this
may lead to serious injury or property damage. Always do as follows.
q Checks after operation (with engine stopped)

q Have any inspection and maintenance points been forgotten?
q Have all inspection and maintenance items been carried out correctly?
q 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.
q Is there any leakage of water or oil? Have all the bolts been tightened?
q Check when the engine is running
q See “TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING (2-31)“ in the section on
safety for checking when the engine is running. Pay attention to safety.
q Check if the inspected and maintenance area is operating normally
q Increase the engine speed to check for fuel and oil leakage.
4-3
OUTLINES OF SERVICE MAINTENANCE
OUTLINES OF SERVICE 4
HANDLING OIL, FUEL, COOLANT, GREASE AND CARRYING OUT KOWA

(Komatsu Oil Wear Analysis) 4
OIL 4
q Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pres-
sure), and deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Man-
ual.
Even if the oil is not dirty, always change the oil after the specified interval.
q Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of problems with machines are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
q Never mix oils of different grades or brands.

q Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
q If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
q When changing the oil, always replace the related filters at the same time.
q We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.
FUEL 4
q The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
q Be extremely careful not to let impurities get in when storing or adding fuel.
q Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15°C
(5°F)). It is necessary to use the fuel that is suitable for the temperature.
q To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel
tank after completing the day's work.
q Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water
from the fuel tank.
q If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.
4-4
MAINTENANCE OUTLINES OF SERVICE
COOLANT 4
q River water contains large amount of calcium and other impurities, so if it is used, scale will stick to the engine
and radiator, and this will cause defective heat exchange and overheating.
Do not use water that is not suitable for drinking.

q When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
q This antifreeze is also effective in preventing corrosion on the parts of the engine cooling system. It may be
continuously used for two years or 4000 hours of operation, therefore it may be used throughout the year.
q Antifreeze is flammable, so be extremely careful not to expose it to flame or fire.
q The proportion of antifreeze to water differs according to the ambient temperature.
For details of the mixing proportions, see “CLEAN INSIDE OF COOLING SYSTEM (4-23)“.
q If the engine overheats, wait for the engine to cool before adding coolant.
q If the coolant level is low, it will cause overheating and will also cause problems with corrosion from the air in
the coolant.
GREASE 4
q Grease is used to prevent twisting and noise at the joints.
q The nipples not included in the maintenance section are nipples for overhaul, so they do not need grease.
If any part becomes stiff after being used for long time, add grease.
q 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.
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) 4

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 abnormalities.
Periodic use of KOWA makes the following possible:
q It enables abnormalities to be detected early, leading to reduction of repair costs and machine downtime.
q It enables repair schedules to be planned, leading to improved machine availability.
KOWA analysis items
q Analysis of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to

measure the density of metal wear particles in the oil.
4-5
OUTLINES OF SERVICE MAINTENANCE
q Measurement of particle quantity

This uses a PQI (Particle Quantifier Index) measurer to
measure the quantity of large iron particles in the oil.
q Others
Measurements are made of items such as the ratio of water or fuel in the oil, and the dynamic viscosity.
Oil sampling
q Sampling interval
250 hours: Engine
500 hours: Other components
q Precautions when sampling
q Make sure that the oil is well mixed before sampling.
q Carry out sampling regularly at fixed intervals.
q Do not carry out sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, please contact your Komatsu distributor.
STORING OIL AND FUEL 4

q Keep indoors to prevent any water, dirt, or other impurities from getting in.
q When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at
the side to prevent moisture from being sucked in.
If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures to protect
them.
q 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).
FILTERS 4
q Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
q Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
q When replacing oil filters, check if any metal particles are affixed to the old filter. If any metal particles are
found, please contact your Komatsu distributor.
q Do not open packs of spare filters until just before they are to be used.
q Always use Komatsu genuine filters.
4-6
MAINTENANCE OUTLINES OF SERVICE
BIODEGRADABLE HYDRAULIC OIL AND LUBRICANTS 0.

The use of biodegradable hydraulic oils and lubricants - on the basis of synthetic esters - for Komatsu machines is
permitted. For information on the products cleared for use and best suited for your application contact our autho-
rized service workshops.
OUTLINE OF ELECTRIC SYSTEM 4

q It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged.
This will cause an electrical short circuit 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.
q Service relating to the electric system is checking fan belt tension, checking damage or wear in the fan belt
and checking battery fluid level.
q Never install any electric components other than those specified by Komatsu.
q External electro-magnetic interference may cause malfunction of the control system controller, so before
installing a radio receiver or other wireless equipment, please contact your Komatsu distributor.
q When working at the seashore, carefully clean the electric system to prevent corrosion.
q The optional power source must never be connected to the fuse, starting switch, or battery relay.
4-7
WEAR PARTS MAINTENANCE
WEAR PARTS 4
Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before
they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of
the machine. When replacing parts, always use Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check the latest part number when ordering parts.
WEAR PARTS LIST 4

The parts in parentheses are to be replaced at the same time.
*: See Part No. in Parts Book (Komatsu).
Item Part No. Part Name Q'ty Replacement frequency

Engine oil filter * Cartridge 1 EVERY 500 HOURS
Fuel filter * Cartridge 1 EVERY 500 HOURS
HST filter * Cartridge 1 EVERY 1000 HOURS
Transfer strainer * O-ring 1 EVERY 1000 HOURS
Hydraulic filter * Cartridge 1 EVERY 2000 HOURS
Hydraulic tank breather * Element 1 EVERY 2000 HOURS
Air cleaner * Element ass'y 1 -
fresh * Element 1 EVERY 2000 HOURS
Air conditioner filter
recirc * Element 2 EVERY 2000 HOURS
Center edge 1
Side edge 2
Bolt on cutting edge * (Bolt) (8) -
(Nut) (8)
(Washer) (8)
Electrical intake airheater * Gasket 2 -
4-8
MAINTENANCE FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS 4
LUBRICATION CHART
WA320-5gb-oilchart-2
1. Lubrication intervals are based on the service meter reading.

2. Abbreviations:
EO = Engine Oil, G = Lithium Grease No. 2, F = Diesel Fuel, AXO = Axle Oil, HO = Hydraulic Oil.
3. Numbers at the left side of the chart indicate the number of lubrication points. Refer to the above illustration.
4. Fuel filter, engine oil filter, HST filter element should be renewed after the initial 250-hour operation and there-
after at change period as shown in this chart.
5. Refer to operation and maintenance manual for details.
Binding is the maintenance schedule chart in operation and maintenance manual on page 4-17.
4-9
FUEL, COOLANT AND LUBRICANTS MAINTENANCE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS 4
LUBRICANTS, FUELS AND FILLING CAPACITIES
WA320-5H Lubricant and Filling

Short code / Temperature Viscosity
operating Quality grade capacitiy in
cask lettering range range
medium litres
EO 0030A -30° up to 40° C SAE 0W-30
CCMC D4
EO 0540A -25° up to 40° C SAE 5W-40
or, if not available:
EO 10 -20° up to 10° C SAE 10 20
Engine Engine oil API CD or
EO 30 0° up to 40° C SAE 30 (19,5 **)
API CE or
EO 1030A -20° up to 40° C SAE 10W-30
API CF -4
EO 1540A - 15° up to 50° C SAE 15W-40 *)
CCMC D4
or, if not available: 8,0
Transfer case Engine oil EO 10 -30° up to 40° C SAE 10W*)
API CD or API CE or (6,5 **)
API CF -4
Hydraulic ISO VG46 *) 155
Hydraulic oil HYD 0530 HVLP, HVLP D -30° up to 40° C
system (1) (89**)
AXO 80 (*2) -30° up to 40°C 80W
Axle oil AXO Fuchs: TITAN
Axle with HYDRA ZF 20W-40 -10° up to 45° C SAE 20W-40 *)
standard CCMC D4
differential or, if not available:
or Engine oil EO 30 0° up to 40° C SAE 30 each 24
API CD or API CE or
(each 24**)
API CF -4
Shell: DONAX TD 5W-30*** SAE 5W-30
Axle with
Esso: TORQUE FLUID56****
limited-slip Axle oil (*4) AXO
Mobil: MOBILFLUID 424
differential (*3)
Fuchs: TITAN HYDRA ZF 20W-40 SAE 20W-40 *)
ASTM D975 No.1 -30° up to -10° C
ASTM D975 No.2 -10° up to 40° C
Fuel tank Diesel fuel CFPP class B 0° up to 40° C ----- 228
DIN-EN 590 CFPP class D -10° up to 40° C
CFPP class F -20° up to 40° C
Multi purpose
Grease nippels grease on a MPG-A KP2N-20 -30° up to 40° C NLGI-No. 2 ---
lithium base
Grease box of Multi purpose
central lubrica- grease on a MPG-A KP2N-20 -30° up to 40° C NLGI-No. 2 ---
tion unit lithium base
Water and
Cooling system SP-C Add antifreeze with corrosion resistor 20
coolant
Air conditioner Coolant NRS R134a (CFC-free) 860 g
* Work filling
** Top-up quantity
*** North American manufacted DONAX TD 20W-40 must not be used.
**** North American manufacted TORQUE FLUID 56 must not be used.
(1): Please use SAE10W30 for the oil in the hydraulic system. If Komatsu genuine oil is not available, select the oil
from the table below.
Supplier Engine oil (The 15W40 oil marked * is CE.)

BP Vanellus C3 (15W40)
Essolube D3, *Essolube XD-3, *Essolube XD-3 Extra, *Essolube heavy duty,
EXXON(ESSO)
Exxon heavy duty
GULF Super duty motor oil, *Super duty plus
MOBIL Delvac 1300, *Delvac super (10W-30, 15W-40)
SHELL Rimura X, Rotella T 10W30
4-10
*2: For the standard differential, except for “AXO80“, the oil for machines equipped with the limited-slip differential
in the table below and E030 can be used. However, in the case of “E030“, depending on conditions such as the
way the brakes are used and the oil temperature, the brakes may squeal just before the machine stops, but there
is no problem with the brake performance or durability.
*3: The letters “ASD“ are stamped on the name plate of machines equipped with the limited-slip differential axle.
*4: For machines equipped with the limited-slip differential axle, select from the oil given in the table below.
Never use any oil except the oil listed in the table below.
Maker Brand Remarks

SHELL DONAX TD 5W-30 North American manufactured DONAX
TD 20W-40 must not be used
ESSO TORQUE FLUID 56 North American manufactured must not
be used
MOBIL MOBILFLUID 424
FUCHS RENOGEAR HYDRA ZF 20W-40
4-11
REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance hours
described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
When starting the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine oil of
SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C (50°F) more
or less during the day.
Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.
There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add sin-
gle grade oil that matches the temperature range in the table.
We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and
hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Change interval of oil in

Fuel sulphur content
engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
4-12
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT(Winter, one
EO15-40CD season type)
Diesel sigma S
super dieselmulti-
2 AGIP Rotra MP GR MU/EP -
grade
*Sigma turbo
Multi-purpose gear PYKON premium
3 AMOCO *Amoco 300 -
oil grease
Litholine HEP 2
4 ARCO *Arcofleet S3 pius Arco HD gear oil -
Arco EP moly D
Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP
*RPM delo 400 Universal thuban Marfak all purpose 2
6 CALTEX AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C
8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 -
Universal gear
9 CONOCO *Fleet motor oil Super-sta grease -
lubricant
Multiperformance 3C Tranself EP
10 ELF - Glacelf
Performance 3C Tranself EP type 2
Essolube D3
*Essolube XD-3
EXXON Gear oil GP
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant
Delvac 1300 Mobilux EP2
Mobilube GX
13 MOBIL *Delvac super Mobilgease 77 -
Mobilube HD
10W-30, 15W-40 Mobilgrease special
4-13
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
Multi-purpose white
*Superme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White-bearing summer coolant
grease
PETRO- FINA potonic N
15 FINA kappa TD FINA marson EPL2 FINA tamidor
FINE FINA potonic NE
Spirax EP
16 SHELL Rimura X Albania EP grease -
Spirax heavy duty
Sunoco ultra prestige Sunoco antifreeze
Sunoco GL5
17 SUN - 2EP and summer cool-
gear oil
Sun prestige 742 ant
*Ursa super plus Multifak EP2 Coda 2055 startex
18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant
Total EP
Rubia S
19 TOTAL Total Transmission Multis EP2 Antigal/antifreeze
*Rubia X
TM
20 UNION *Guardol MP gear lube LS Unoba EP -
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B - Antifreeze
MDC Multigear C
4-14
MAINTENANCE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
STANDARD TIGHTENING TORQUES FOR BOLTS AND

NUTS 4
TORQUE LIST 4
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to
the tightened parts, and this will cause failure of the machine or problems with operation.
Always pay careful attention when tightening parts.
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that
was replaced.
Thread Width Tightening torque

diameter across Target value Service limit
of bolt flats
(a)(mm) (b)(mm) N·m kgf·m lbft N·m kgf·m lbft
6 10 13.2 1.35 9.8 11.8-14.7 1.2-1.5 8.7-10.8
8 13 31 3.2 23.1 27-34 2.8-3.5 20.3-25.3
10 17 66 6.7 48.5 59-74 6.0-7.5 43.4-54.2
12 19 113 11.5 83.2 98-123 10.0-12.5 72.3-90.4
14 22 172 17.5 126.6 153-190 15.5-19.5 112.1-141
16 24 260 26.5 191.7 235-285 23.5-29.5 170.0-213.4
18 27 360 37 267.6 320-400 33.0-41.0 238.7-296.6
20 30 510 52.3 378.3 455-565 46.5-58.0 336.3-419.5
22 32 688 70.3 508.5 610-765 62.5-78.0 452.1-564.2
24 36 883 90 651 785-980 80.0-100.0 578.6-723.3
27 41 1295 132.5 958.4 1150-1440 118.0-147.0 853.5-1063.3
30 46 1720 175.0 1265.8 1520-1910 155.0-195.0 1121.1-1410.4
33 50 2210 225.0 1627.4 1960-2450 200.0-250.0 1446.6-1808.3
36 55 2750 280.0 2025.2 2450-3040 250.0-310.0 1808.3-2242.2
39 60 3280 335.0 2423.1 2890-3630 295.0-370.0 2133.7-2676.2
Apply the following table for Hydraulic Hose.
Width Tightening torque

across Target value Permissible range
Nominal - No.
flats
of threads (a)
(b) N·m kgf·m lbft N·m kgf·m lbft
(mm)
9/16 -18UNF 19 44 4.5 32.5 35 - 63 3.5 - 6.5 25.3 - 47.0
11/16 -16UN 22 74 7.5 54.2 54 - 93 5.5 - 9.5 39.8 - 68.7
13/16 -16UN 27 103 10.5 75.9 84 - 132 8.5 - 13.5 61.5 - 97.6
1 -14UNS 32 157 16.0 115.7 128 - 186 13.0 - 19.0 94.0 - 137.4
13/16 -12UN 36 216 22.0 159.1 177 - 245 18.0 - 25.0 130.2 - 180.8
4-15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS MAINTENANCE
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4

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 important parts.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However,
it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is
required to replace them with new ones regardless of their condition after a certain period of usage. This is impor-
tant 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 peri-
odic 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 carry out the following checks with hydraulic hoses which need not be replaced periodically. Tighten a loos-
ened clamp or replace a defective hose, as required.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.
Ask your Komatsu distributor to replace the critical parts.
Replacement inter-
No. Safety critical parts for periodic replacement Q'ty
val
1 Fuel hose (fuel tank - water separator) 1
2 Fuel hose (water separator - pump) 1
3 Fuel return hose (pump - fuel tank) 1
4 Fuel spill hose (tube - fuel tank) 1
5 Turbocharger lubricating hose 1
6 Steering hose (pump - priority valve) 1
7 Steering hose (priority valve - orbitrol valve) 1
8 Steering hose (orbitrol valve - steering cylinder) 6
Every 2 years or
9 Steering hose (steering cylinder line - cushion valve) 2 every 4000 hours,
10 Packings, seals, O-rings of steering cylinder 2 whichever
comes first
11 Brake hose (gear pump - master cylinder) 1
12 Brake hose (master cylinder - front brake) 2
13 Brake hose (master cylinder - rear brake) 2
14 Brake hose (master cylinder - accumulator) 2
15 Brake hose (accumulator - charge valve) 2
16 Brake hose (master cylinder - hydraulic tank) 1
17 Brake hose (charge valve - hydraulic tank) 1
18 O-rings and oil seals of brake valve 7
4-16
MAINTENANCE MAINTENANCE SCHEDULE CHART
MAINTENANCE SCHEDULE CHART 4
MAINTENANCE SCHEDULE CHART 4

INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
REPLACE HST OIL FILTER ELEMENT ........................................................................................................... 4-534

REPLACE HYDRAULIC FILTER ELEMENT .................................................................................................... 4-554
WHEN REQUIRED
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT ........................................................................... 4-204

DUST PRE-EXTRACTOR "TURBO II": CHECK, CLEAN................................................................................. 4-224
CLEAN INSIDE OF COOLING SYSTEM.......................................................................................................... 4-234
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL ...................................................................................... 4-264
CHECK AXLE OIL LEVEL, ADD OIL ................................................................................................................ 4-274
CLEAN AXLE CASE BREATHER..................................................................................................................... 4-284
CLEAN AIR CONDITIONER CONDENSER ..................................................................................................... 4-294
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID .............................................................................. 4-294
CLEAN RADIATOR FINS AND COOLER FINS ............................................................................................... 4-304
CLEAN TRANSFER OIL COOLER FINS.......................................................................................................... 4-314
CHECK ELECTRICAL INTAKE AIR HEATER.................................................................................................. 4-314
REPLACE BOLT ON CUTTING EDGE ............................................................................................................ 4-324
REPLACE BUCKET TEETH ............................................................................................................................. 4-334
CHECK AIR CONDITIONER ............................................................................................................................ 4-344
REPLACE SLOW BLOW FUSE........................................................................................................................ 4-354
SELECTION AND INSPECTION OF TIRES..................................................................................................... 4-364
CHECK BEFORE STARTING
CHECK BEFORE STARTING........................................................................................................................... 4-38
EVERY 50 HOURS SERVICE
DRAIN WATER, SEDIMENT FROM FUEL TANK ............................................................................................ 4-394
LUBRICATE REAR AXLE PIVOT PIN .............................................................................................................. 4-404

CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..................................................................... 4-404
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ..................................................................................... 4-414
CHECK BATTERY ELECTROLYTE LEVEL..................................................................................................... 4-424

CHECK PARKING BRAKE ............................................................................................................................... 4-444
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST ...................................................... 4-444
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN................................................................................... 4-454
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER........................................................... 4-464
LUBRICATING .................................................................................................................................................. 4-464
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ..................................... 4-484
REPLACE FUEL FILTER CARTRIDGE............................................................................................................ 4-494
CLEAN WATER SEPARATOR STRAINER...................................................................................................... 4-504
4-17
MAINTENANCE SCHEDULE CHART MAINTENANCE
CHANGE OIL IN TRANSFER CASE ................................................................................................................ 4-514

CLEAN TRANSFER CASE BREATHER .......................................................................................................... 4-524
REPLACE HST OIL FILTER ELEMENT ........................................................................................................... 4-534
LUBRICATING .................................................................................................................................................. 4-544
CHECK TIGHTENING PARTS OF TURBOCHARGER .................................................................................... 4-544
CHECK PLAY OF TURBOCHARGER ROTOR ................................................................................................ 4-544
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT ..................................................... 4-544
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT ....................................... 4-554
REPLACE HYDRAULIC TANK BREATHER ELEMENT .................................................................................. 4-564
CLEANING THE STRAINER OF THE BRAKE FILTER.................................................................................... 4-574
(*)CHANGE AXLE OIL ...................................................................................................................................... 4-584
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER ............ 4-594
CHECK ALTERNATOR, STARTING MOTOR .................................................................................................. 4-594
CHECK ENGINE VALVE CLEARANCE, ADJUST ........................................................................................... 4-594
CHECK BRAKE DISC WEAR ........................................................................................................................... 4-594
CLEAN AND CHECK TURBOCHARGER ........................................................................................................ 4-604
CHECK ACCUMULATOR GAS PRESSURE ................................................................................................... 4-604
CHECK VIBRATION DAMPER......................................................................................................................... 4-604
*: The interval of 2000 hours for changing the axle oil is for standard operations. If the brake is used frequently or
the brakes make a sound, change the oil after a shorter interval.
LUBRICATING .................................................................................................................................................. 4-614

CHECK WATER PUMP .................................................................................................................................... 4-614
4-18
MAINTENANCE SERVICE PROCEDURE
SERVICE PROCEDURE 4
INITIAL 250 HOURS SERVICE 4

Carry out the following maintenance only after the first 250 hours.
q REPLACE HST FILTER ELEMENT
q REPLACE HYDRAULIC FILTER ELEMENT
For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS and 2000 HOURS
SERVICE.
4-19
SERVICE PROCEDURE MAINTENANCE
WHEN REQUIRED 4
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT 4
WARNING
q If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the
engine and damage it. Always stop the engine before carrying out these operations.
q When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use safety glasses, dust mask, and other protective equipment.
CHECKING
If air cleaner clogging caution lamp (1) on the machine monitor

lights up, clean the air cleaner element.
NOTICE
Do not clean the element until the air cleaner clogging cau-
tion lamp lights up.
If the element is cleaned frequently before the air cleaner
clogging caution lamp lights up, the air cleaner will not be
able to display its performance fully and the cleaning effi-
ciency will drop.
In addition, the frequency of dirt stuck to the element fall-
ing inside the inner element will increase.
CLEANING OUTER ELEMENT
1. Open the engine side cover on the right side of the

machine.
2. Remove three clips (2), then remove cover (3).
NOTICE
Never remove inner element (5). If it is removed, dust will
enter and cause engine trouble.
3. Remove outer element (4).
4-20
4. Clean the interior of the air cleaner body, cover (3) and
evacuator valve (6).
NOTICE
The inner element must not be used again even after its
cleaning. When replacing the inner element, replace the
outer element at the same time.
5. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm2, 99.4

PSI)) from the inside of the outer element along its folds.
Then direct the compressed air from the outside along the
folds, and again from the inside.
6. Replace any outer element, which has been cleaned 6

times or used for one year. Replace the inner element at
the same time.
7. Replace both inner and outer elements when the air

cleaner clogging caution lamp lights up immediately after
installing the cleaned outer element even though it has not
been cleaned 6 times.
8. If small holes or thinner parts are found on the element

when it is checked by shining a light through it after clean-
ing, replace the element.
NOTICE
When cleaning the element, do not hit or beat it against
anything.
Do not use an element whose folds, gasket or seal are
damaged.
CAUTION
When installing the cover (3), check O-ring (7) and replace it if there are any scratches or damage.
9. Set the cleaned outer element in position, then secure cover (3) with mounting clips (2).
4-21
REPLACING ELEMENT

machine.
2. Remove three clips (2), then remove cover (3).
3. Remove outer element (4).
Do not remove inner element (5) at this time, however.
4. Clean the interior of the air cleaner body, cover (3) and
evacuator valve (6).
5. Remove inner element (5), then install a new inner element immediately.
6. Fit new outer element (4), replace O-ring (7) with a new part, install cover (3), then secure with clips (2).
DUST PRE-EXTRACTOR "TURBO II": CHECK, CLEAN

(This pre-extractor is an optional extra)
The intake screen and the dust extractor gap (at the bottom cir-
cumference of the pre-extractor) must always be kept clean.
The pre-extractor should be unscrewed and its condition
checked from time to time depending on use. If necessary,
blow out the pre-extractor from the inside.
4-22
CLEAN INSIDE OF COOLING SYSTEM 4
WARNING
q Immediately after the engine is stopped, the engine coolant is hot and the pressure inside the radiator
is high. Removing the cap and draining the water under this condition could cause burns. Allow the
engine to cool down. To loosen and remove the radiator cap, use a suitable climbing aid (for example
a ladder) to climb up the back of the machine. Then turn the cap slowly to release the pressure.
q Start the engine and flush the system. When standing up or leaving the operator's seat, set the safety
lock lever to the LOCK position.
q For details of starting the engine, see “CHECK BEFORE STARTING ENGINE, ADJUST (3-54)“ and
“STARTING ENGINE (3-70)“ in the OPERATION section of the Operation and Maintenance Manual.
q When the undercover is removed, there is danger of touching the fan.
Never go to the rear of the machine when the engine is running.
Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the
table below.
Cleaning inside of Adding corrosion

Kind of coolant cooling system and resistor agent KI
changing coolant (No. 600-411-1120)
Every year (autumn) or
Permanent type antifreeze
every 2000 hours
(All season type)
whichever comes first
Non-permanent type Every 6 months (spring Every 1000 hours and
antifreeze containing and autumn) when cleaning the inside
ethylene glycol (winter, (Drain antifreeze in spring, of the cooling system and
one season type) add antifreeze in autumn) when changing coolant.
Every 6 months or every
When not using antifreeze 1000 hours whichever
comes first
Stop the machine on level ground when cleaning the inside of cooling system or changing the coolant.
Use a permanent type of antifreeze.
If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol.
Super Coolant (AF-ACL) has an anti-corrosion effect as well as an antifreeze effect.
The ratio of antifreeze to water depends on the ambient temperature, but to obtain the corrosion resistance effect,
a minimum ratio of 30% by volume is necessary.
In areas where the water is hard, always add Komatsu genuine corrosion resistor agent KI. One packet of corro-
sion resistor (No. 600-411-1120) agent contains 100g (0.22 lb). The standard density of the mixture should be 7g/
liter (0.065 oz/US gal).
4-23
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mix-
ing rate table given below.
It is actually better to estimate a temperature about 10°C (50°F) lower when deciding the mixing rate.
Mixing rate of water and antifreeze
Min. atmospheric °C -10 -15 -20 -25 -30

temperature °F 14 5 -4 -13 -22
Amount of anti- Liter 6.0 7.2 8.2 9.1 10.0
freeze US gal 1.59 1.90 2.17 2.40 2.64
Liter 14.0 12.8 11.8 10.9 10.0
Amount of water
US gal 3.69 3.38 3.11 2.88 2.64
WARNING
Antifreeze is flammable, so keep it away from flame.
Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on
you. If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.
Use city water for the cooling water.
If river water, well water or other such water supply must be used, contact your Komatsu distributor.
We recommend use of an antifreeze density gauge to control the mixing proportions.
q Prepare a container to catch drained coolant: Min 20 liters (5.28 US gal) capacity.
q Prepare a water inlet hose.
1. Stop the engine.
2. To loosen and remove the radiator cap, use a suitable

climbing aid (for example a ladder) to climb up the back of
the machine.
3. Check that the cooling water temperature has gone down

enough to make it possible to touch the radiator cap sur-
face by hand, then turn radiator cap (1) slowly until it con-
tacts the stopper to release the pressure.
4. Following this, push radiator cap (1), turn it until it contacts

the stopper, then remove it.
4-24
5. Set a container in position to catch drained antifreeze mix-

ture, then open valve (2) under the radiator to drain cooling
water.
6. After draining the water, close drain valve (2) and fill with
tap water.
7. When the radiator is full, start the engine, and run it at low
idling.
Keep the engine running at low idling for 10 minutes until

the water temperature reaches more than 90°C (194°F).
8. Stop the engine, open drain valve (2), drain the water, then
tighten them again.
9. After draining the water, clean the cooling system with cleaning agent.
For the cleaning method, see the instructions for the cleaning agent.
10. Decide the proportions of antifreeze and water according to the table for the mixing rate of water and anti-
freeze.
11. To remove the air in the cooling system, run the engine for 5 minutes at low idling, and for another 5 minutes at
high adling. (When doing this, leave the radiator cap off.)
12. After draining off the cooling water of reserve tank (3) ,
clean the inside of the reserve tank and refill the water
between FULL and LOW level.
13. Stop the engine. About 3 minutes later, supply city water
up to the water filler, then close radiator cap.
4-25
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL 4
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns.
Wait for the temperature to go down before starting the work.
Carry out this procedure if there is any sign of oil on the transfer case.
1. Start the engine and run it at low idling for at least 5 minutes.
2. Open the cap of oil filler port (F), remove dipstick (G), and
wipe the oil off with a cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.
4. The oil level should be between the H and L marks on dip-

stick (G).
If the oil level is below the L mark, add oil through oil filler
(F).
5. If the oil is above the H mark, drain the excess engine oil
from drain plug (P), and check the oil level again.
6. If the oil level is correct, insert dipstick (G) in the dipstick

guide, then tighten the cap.
4-26
CHECK AXLE OIL LEVEL, ADD OIL 4
WARNING
q When checking the oil level, apply the parking brake and secure the front and rear frames with the
safety bar.
q After stopping the engine, the parts and oil are at a high temperature. Wait for the temperature to go
down before starting the operation.
Carry out this procedure if there is any sign of oil on the axle case.
Carry out the inspection with the machine on a horizontal road surface.
(If the road surface is at an angle, the oil level cannot be checked correctly.)
q A: Front B: Rear
1. Stop the engine and remove oil level plug (1).
REMARK
Remove the mud and dirt from around plug (1), then remove
the plug.
2. Wipe off any oil adhering to the oil level gauge attached to
plug (1) with cloth.
4-27
3. Set the oil level gauge (G) as shown in the right diagram.
4. The oil level is correct when it is between the two lines pro-
vided on the oil level gauge.
If the oil level does not reach the lower line, add axle oil
through filler port (F).
5. If the oil level is above the upper line, drain off the excess
oil through drain plug (P) and check the oil level again.
6. If the oil level is correct, install plug (1).
Tightening torque: 93 to 123 N·m (9.5 to 12.5 kgf·m, 68.7 to

90.4 lbft)
CLEAN AXLE CASE BREATHER 4
WARNING
When cleaning the axle breather, apply the parking brake
and secure the front and rear frames with the safety bar.
q A: Front B: Rear
Remove all mud and dirt from around the breather with a
brush.
After removing the mud or dirt from around the breather,

remove the breather, immerse it in cleaning fluid and clean it.
When cleaning the breather, clean the breathers at two places

(front and rear).
After removing the breather, take steps to prevent dirt or dust

from entering the mount.
4-28
CLEAN AIR CONDITIONER CONDENSER 4
WARNING
q Do not wash the condenser with a steam cleaner. There is danger that the condenser could overheat.
q If high-pressure water hits your body directly or dirt is sent flying, there is danger of personal injury.
Always wear protective glasses, dust mask, and other protective equipment.
If there is mud or dust on the air conditioner condenser, clean it with water.
If the water pressure is too high, the fins may get deformed. When washing with a high pressure washing
machine, apply the water from a reasonable distance.
WASHING METHOD
1. Open top cover (1) at the front of the engine hood.
2. Remove 2 mounting bolts (3) at the top of condenser (2).
3. Hold the top of condenser (2) and tip it to the rear. A gap is
formed between the engine hood and condenser.
4. Wash with water from the top.
5. Pull condenser (2) back to the original position and fit bolt
(3).
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID 4
Check the washing fluid levels in washer tank (1). When the
fluid has run low, add automotive window washing fluid.
Be careful not to let dust get into the fluid.
4-29
CLEAN RADIATOR FINS AND COOLER FINS 4
WARNING
q Never open the engine side cover when the engine is running. Stop the engine completely before
starting the cleaning operation.
q If compressed air, pressurized water, or steam hits your body directly, or causes dirt to fly, it may lead
to personal injury. Always wear safety glasses, dust mask, or other protective equipment.
Clean the radiator if mud or dirt is stuck to it.
1. Open rear grill (1).
2. Move lever (3) of fan guard (2) down to release the lock,
then open fan guard (2).
3. Use compressed air to clean the mud, dust, and leaves

from the radiator and oil cooler fins. Steam or water may be
used instead of compressed air.
NOTICE
If the steam jet nozzle is brought too close to the radiator
fins, it may damage the fins, so keep the nozzle a suitable
distance away from the fins when cleaning.
4. Check the rubber hose. Replace with a new one if the hose is found to have cracks or to be hardened by age-
ing.
Also, check hose clamps for looseness.
5. After cleaning, close fan guard (2), apply the lock, then close rear grill (1).
4-30
CLEAN TRANSFER OIL COOLER FINS 4
WARNING
If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by the com-
pressed air, high-pressure water, or steam, there is danger of personal injury. Always wear protective
glasses, dust mask, and other protective equipment.
Clean the oil cooler if mud or dirt is stuck to it.
1. Remove cover (1).
2. Use compressed air to clean the mud, dust, and leaves

from the oil cooler fins (2). Steam or water may be used
instead of compressed air.
3. After cleaning, install the cover (1).
NOTICE
If the steam jet nozzle is brought too close to the oil cooler
fins, it may damage the fins, so keep the nozzle a suitable
distance away from the fins when cleaning.
CHECK ELECTRICAL INTAKE AIR HEATER 4

Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air
heater checked for dirt or disconnections.
4-31
REPLACE BOLT ON CUTTING EDGE 4
WARNING
It is extremely dangerous if the work equipment moves when carrying out the turning or replacement
operation.
Set the work equipment in a stable position, stop the engine, then set the safety lock lever securely to the
LOCK position.
Turn or replace the cutting edge before the wear reaches the edge of the bucket.
1. Raise the bucket to a suitable height, then put blocks (A) under the bucket to prevent the bucket from coming
down.
Raise the bucket so that the bottom surface of the bucket is horizontal.
2. Remove nuts and bolts (1), then remove cutting edge (2).
3. Clean the mounting surface of cutting edge (2).
4. Turn cutting edge (2) and install it to the bucket. When turn-
ing the edge, install it to the opposite side (left edge to right
side, right edge to left side).
If both sides of the cutting edge are worn, replace with a

new part.
If the wear extends to the mounting surface, repair the

mounting surface before installing the cutting edge.
5. Tighten nuts and bolts (1) uniformly so that there is no gap between the bucket and cutting edge.
Tightening torque for mounting bolt: 883 to 1196 N·m (90 to 122 kgf·m, 651 to 882 lbft)
6. Tighten the mounting bolts again after operating for several hours.
4-32
REPLACE BUCKET TEETH 4
WARNING
q If the pin is hit out with strong force, there is danger that the pin may fly out. Check that there is no
one in the surrounding area.
q There is danger of pieces flying during the replacement operation, so always wear protective clothing,
such as safety glasses and gloves.
BUCKET WITH TIP TOOTH
(If equipped)
Replace the teeth before they wear down as far as the adapter.
1. Raise the bucket to a suitable height, then put blocks under the bucket to prevent the bucket from coming
down.
Raise the bucket so that the bottom surface of the bucket is horizontal.
2. Remove pin (2) installed to the bucket, then remove tooth

(1).
Put a rod (slightly narrower than the pin) in contact with the
hatched portion (either left or right) and tap pin (2) out to
the opposite side.
3. Fit new tooth (1) in adapter (3), push in pin (2) partially by
hand, then knock it in with a hammer.
4. After operating the machine for a few hours, check that the
pin does not come out.
4-33
CHECK AIR CONDITIONER 4
CHECK LEVEL OF REFRIGERANT (GAS)
WARNING
If the refrigerant of the conditioner system gets into your
eyes or on your hands, it may cause loss of sight or frost-
bite. Do not touch the refrigerant. Never loosen any part
of the refrigerant circuit.
Do not bring any flame close to any point where the refrig-
erant gas is leaking.
If there is a lack of refrigerant (gas), the cooling performance

will be poor. When operating the cooler at high speed with the
engine at full throttle, use the receiver sight glass (inspection
window) to check the condition of the refrigerant gas (Freon
R134a) flowing in the refrigerant circuit.
q No bubbles in refrigerant flow: Suitable

q Some bubbles in flow (bubbles pass continuously): Lack of
refrigerant
q Colorless, transparent: No refrigerant
REMARK
When there are bubbles, the refrigerant gas level is low, so contact your refrigerant dealer to have refrigerant
added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
OPERATING THE AIR CONDITIONER OFF SEASON
Even during the off-season, operate the air conditioner for 3 - 5 minutes once a month to maintain the oil film at all
parts of the compressor.
4-34
REPLACE SLOW BLOW FUSE 4
q Always turn the power OFF when replacing the slow

NOTICE
blow fuse (turn the starting switch to the OFF posi-

tion).
q Always replace the slow blow fuse with a fuse of the

same capacity.
1. Turn the starting switch to the OFF position.
2. Remove the slow blow fuse box from the chassis.
3. Open covers (1), (2), and (3) of the slow blow fuse box.
Covers (2) and (3) can be removed easily by using protru-

sion (A) on the body as a fulcrum and levering the catch of
the cover with a flat-headed screwdriver to release it.
4. Loosen screws (4) and (5), and remove.
When screws (4) and (5) are removed, slow blow fuse 6
will also come off together with electric wiring (7) and (8).
5. Using screws (4) and (5), install a new slow blow fuse
together with electric wiring 7 and 8 to the slow blow fuse
box, then close covers (1), (2), and (3).
6. Install the slow blow fuse box to the chassis.
4-35
SELECTION AND INSPECTION OF TIRES 4
WARNING
If a tire or a rim is handled wrongly, the tire may burst or
may be damaged and the rim may be broken and scat-
tered, and that can cause serious injury 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 carry out the work.
Do not heat or weld the rim to which the tire is installed. Do
not make a fire near the tire.
SELECTION OF TIRES
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 fol-
lowing table.
Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor
when using optional tires.
Maximum load [kg (lb)] Tire size

Standard Front and Rear 6,775 (14939) 20.5-25-12PR
4-36
CHECK INFLATION PRESSURE OF TIRES
WARNING
When inflating a tire, check that no one will enter the work-
ing area. Use an air chuck which has a clip and which can
be fixed to the air valve.
While inflating the tire, check the inflation pressure occa-
sionally so that it will not rise too high.
If the rim is not fitted normally, it may be broken and scat-
tered while the tire is inflated. To ensure safety, place a
guard around the tire and do not work in front of the rim
but work on the tread side of the tire.
Abnormal drop of inflation pressure and abnormal fitting
of the rim indicate trouble in the tire or rim. In this case, be
sure to ask a tire repair shop to carry out repairs.
Be sure to observe the specified inflation pressure.
Do not adjust the inflation pressure of the tires just after
high-speed travel or heavy-duty work.
Check
Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.
Inflation of tires
Adjust the inflation pressure properly.
When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not
work in front of the rim but work on the tread side of the tire.
The proper inflation pressure is shown below.
Tire size Inflation pressure

Front tire: 0.32 MPa (3.3 kgf/cm2, 46.9 PSI)
Standard 20.5-25-12PR
Rear tire: 0.27 MPa (2.8 kgf/cm2, 39.8 PSI)
NOTICE
The optimum inflation pressure differs according to the type of work. For details, see “HANDLING THE
TIRES (3-99)“ .
4-37
CHECK BEFORE STARTING 4

For the following items, see “CHECK BEFORE STARTING (3-57)“.
q Check oil level in engine oil pan, add oil

q Check water separator
q Check coolant level, add water
q Check inflation pressure of tires
q Check electric wiring
q Check monitor panel
q Check fuel level, add fuel
q Check parking brake
q Check brake pedal
4-38
EVERY 50 HOURS SERVICE 4
DRAIN WATER, SEDIMENT FROM FUEL TANK 4
Loosen valve (1) on the left side of the tank so that the sedi-
ment and water will be drained together with fuel.
4-39

Maintenance for every 50 hours service should be carried out at the same time.
LUBRICATE REAR AXLE PIVOT PIN 4

(3 places)
1. Using a grease pump, pump in grease through the grease

fittings marked by the arrows.
2. After greasing, wipe off any old grease that was pushed
out.
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER 4
WARNING
If compressed air is used, there is danger that dirt may fly and cause personal injury.
Always wear safety glasses, dust mask, and other protective equipment.
If the air conditioner has been used, the air filter should be cleaned.
Stop the air conditioner before cleaning the element.
1. Open cover (1).
2. Remove bracket (2) and filter (3) as one unit.

3. Direct dry compressed air (less than 0.69 MPa (7 kgf/ cm2,
99.4 PSI)) to the element from inside along its folds, then
direct it from outside along its folds and again from inside.
4. When installing, fit filter (3) into bracket (2), then install.
4-40
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL 4
WARNING
q The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for
the temperature to go down before starting the work.
q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1. Lower the bucket horizontally to the ground and stop the

engine. Wait for 5 minutes, then check sight gauge (G).
The oil level should be between the H and L marks.
NOTICE
Do not add oil above the H line. This will damage the
hydraulic circuit or cause the oil to spurt out. If oil has
been added to above the H level, stop the engine and wait
for the hydraulic oil to cool down. Then place a container
under the drain valve (3) to catch the oil, remove drain
plug (P) and loosen drain valve (3) to drain the excess oil
into the container.
2. If the oil is below the L level, add oil to the hydraulic tank as
follows.
2. Keep lock pin (2) pulled, then turn oil filler cap (F) coun-
terclockwise and remove it.
3. Refill the specified quantity of oil through oil filler (F).
4. After adding oil, install oil filler cap (F) and cover (1).
4-41

Maintenance for every 50 and 100 hours service should be carried out at the same time.
CHECK BATTERY ELECTROLYTE LEVEL 4

Carry out this check before operating the machine.
WARNING
q Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will acceler-
ate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it
may also cause an explosion.
q The battery generates flammable gas and there is danger of explosion, so do not bring fire or sparks
near the battery.
q Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount
of water and consult a doctor.
q When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER
LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or
corrode other parts.
NOTICE
When adding distilled water in cold weather, add it before starting operations in the morning to prevent
the electrolyte from freezing.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY
If it is possible to check the electrolyte level from the side of the battery, check as follows.
1. Open the cover of the battery box.
There are two battery boxes: One on each side at the rear of the machine.
2. Use a wet cloth to clean the area around the electrolyte

level lines and check that the electrolyte level is between
the UPPER LEVEL (Maximum) and LOWER LEVEL (Mini-
mum) lines.
If the battery is wiped with a dry cloth, static electricity may

cause a fire or explosion.
4-42
3. If the electrolyte level is below the midway point between

the UPPER LEVEL and LOWER LEVEL lines, remove cap
(1) and add distilled water to the UPPER LEVEL line.
4. If distilled water has been added to any cell of cap (1), add
distilled water also to the other cells.
5. Clean the vents of the battery caps, then close the caps
securely.
Keep the top of the battery clean and wipe it with a wet
cloth.
REMARK
If distilled water is added to above the UPPER LEVEL line, use a syringe to lower the level to the UPPER LEVEL.
line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of
water or consult your Komatsu distributor or battery maker.
WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY
If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER
LEVEL line on the side of the battery, check as follows.
1. Open the cover of the battery box.
There are two battery boxes: One on each side at the rear of the machine.
2. Remove cap (1) at the top of the battery, look through the
water filler port, and check the electrolyte surface. If the
electrolyte does not reach the sleeve, add distilled water so
that the level reaches the bottom of the sleeve (UPPER
LEVEL line) without fail.
3. If distilled water has been added to any cell of cap (1), add
distilled water also to the other cells.
Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.
4. After adding distilled water, tighten cap (1) securely.
4-43
REMARK
If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the
sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount
of water or consult your Komatsu distributor or battery maker.
WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL

If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
CHECK PARKING BRAKE 4

Test conditions
q Tire inflation pressure: as specified
q Road surface: Dry paved surface with 25% grade

Lock
q Machine: Operating condition
Test method Free

1. Start the engine and set the work equipment to the travel
posture. 9EA04476-A
2. Align the machine facing straight to the front, then drive the
machine up a 25% grade with the bucket empty.
3. Apply the brake to stop the machine, return the directional
lever to the neutral position ‚N', set the parking brake to the
LOCK position and stop the engine.
4. Release the brake pedal slowly and check whether the
machine is held in Stop position.
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST 4
CHECKING
1. Open the engine side cover on the left side of the chassis.
2. Standard deflection “a“ between air conditioner compres-

sor pulley (1) and fan pulley (2) when pressed with a thumb
(approx. 98 N (10 kg)) should be approx. 9.5 to 13.5 mm
(0.4 to 0.5 in).
When a belt tension gauge is used, the standard tension is

within a range of 353 to 549 N (36 to 54 kgf).
4-44
CHECK WHEN CHANGING THE V-BELT
The standard deflection between the air conditioner compressor pulley and fan pulley when pressed with a thumb
(approx. 98 N (10 kgf)) should be approx. 7 to 10 mm (0.28 to 0.4 in).
When a belt tension gauge is used, the standard tension is within a range of 533 to 745 N (54 to 76 kgf).
REMARK
When the belt has been replaced with a new part, a high tension is necessary, so the initial tension is in the value
given above.
ADJUSTING

machine.
2. When adjusting, loosen 4 bolts (1), turn 2 adjustment bolts

(2), and move bracket (3) and the compressor as one unit.
3. After adjusting, tighten bolts (1) and the locknut of bolts (2).
q Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to
NOTICE
check that the V-belt is not touching the bottom of the V-groove.
q In case any of the following occurs, ask the Komatsu distributor in your territory to replace the belts
with new ones.
〈 The fan belt has elongated, leaving little allowance for adjustment.
〈 A cut or crack is found on the belt.
〈 Slipping or creaking sound is heard coming from the belt.
q When the new V-belt is set, readjust it after one hour of operation.
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN 4
If wheel hub nuts (1) are loose, tire wear will be increased and
may cause accidents.
1. Check for loose nuts, and tighten if necessary.
When checking for loose nuts, always turn the nuts in the
direction of tightening to check.
Tightening torque: 824 to 1030 N·m (84 to 105 kgf·m, 607.6

to 759.5 lbft)
2. If any stud bolt is broken, replace all the stud bolts for that
wheel.
4-45
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER 4
1. Loosen knob (1), remove filter inspection cover (2), then

open filter inspection cover (3).
2. Pull out filters (4) and (5) in the direction of the arrow.
3. Clean with compressed air in the same way as for the fresh
air filter.
If the filter is extremely dirty, rinse it in water.
After rinsing the filter, dry it completely before installing it

again.
LUBRICATING 4
NOTICE
On jobsites where there is a lot of heavy-duty work, or on jobsites where operations are carried out contin-
uously for more than eight hours, reduce the greasing interval and carry out greasing more frequently.
1. Put the work equipment horizontally in contact with the

ground, then stop the engine.
2. Using a grease pump, pump in grease through the grease

fittings marked by the arrows.
3. After greasing, wipe off any old grease that was pushed
out.
(1) Bucket pin (2 places)

(2) Bucket link pin (2 places)
4-46
(3) Dump cylinder pin (2 places)

(4) Lift cylinder pin (4 places)
(5) Lift arm pivot pin (2 places)
(6) Tilt lever pin (1 place)
(7) Steering cylinder pin (4 places)
4-47

Maintenance for every 50, 100 and 250 hours service should be carried out at the same time.
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4
WARNING
q Refill capacity: 19.5 liters (5.15 US gal)
q Filter wrench
2. Open oil filler (F).
3. Place a container to catch the oil under drain plug (P).
4. Loosen drain plug (P) and drain the oil. Be careful not to
get oil on yourself.
5. Check the drained oil, and if there are excessive metal par-
ticles or foreign material, please contact your Komatsu dis-
tributor.
6. Tighten drain plug (P).
7. Open the engine side cover on the left side of the chassis.
8. Using the filter wrench, turn filter cartridge (1) counter-

clockwise to remove it.
9. Clean the filter holder, fill the new filter cartridge with
engine oil, then coat the seal and thread of the filter car-
tridge with engine oil (or coat thinly with grease) and install.
10. When installing the seal, tighten it so its surface comes into
contact with the filter holder, then tighten another 3/4 turn.
11. After replacing the filter cartridge, add oil through oil filler
(F) until the oil level is between the H and L marks on the
dipstick (G).
12. Run the engine at idling for short time, then stop the
engine, and check that the oil is between the H and L
marks on the dipstick. For details, see “CHECK OIL LEVEL
IN ENGINE OIL PAN, ADD OIL (3-57)“.
4-48
REPLACE FUEL FILTER CARTRIDGE 4
WARNING
q Engine is at high temperature immediately after the machine has been operated. Wait for engine to
cool down before replacing the filter.
q Do not bring fire or sparks near the fuel.
REMARK
If the machine has run out of fuel, use Steps 3 to 10 to bleed the air.
q Container to catch the fuel
q Filter wrench
2. Set the container to catch the fuel under the filter cartridge.
3. Using a filter wrench, turn filter cartridge (1) counterclock-

wise to remove it.
4. Clean the filter holder, fill a new filter cartridge with clean
fuel, coat the packing surface with engine oil, then install it
to the filter holder.
Add fuel from small hole (A) (dirty side) at eight places. Do
not add fuel from hole (B) (clean side) at the center.
NOTICE
If the filter cartridge is tightened excessively, the packing
will be damaged and fuel will leak. If the filter cartridge is
too loose, fuel will also leak from the packing, so always
tighten to the correct amount.
5. When installing, screw in cartridge until seal comes in con-

tact with sealing surface, then tighten approx. an additional
1/2 turn.
6. Add fuel to the fuel tank until the fuel gauge shows Full (F).
7. Loosen air bleed plug (2).

8. Loosen the knob of feed pump (3), then pump it up and down until no more bubbles come out with the fuel
from air bleed plug (2).
9. After bleeding the air, tighten air bleed plug (2), then push in the knob of priming pump (3) and tighten it.
Tightening torque for air bleed plug: 7.8 to 11.8 N·m (0.8 to 1.2 kgf·m, 5.8 to 8.7 lbft)
10. After bleeding the air, start the engine and check that there is no fuel leakage from the filter seal surface. If
there is any leakage, check the tightening of the filter cartridge. If there is still leakage, follow Step 2 and 3 to
remove the filter cartridge, then check the packing surface for damage or foreign material. If any damage or
foreign material is found in the packing, replace the cartridge with a new part, then repeat Steps 4 - 7 to install
the filter cartridge.
4-49
CLEAN WATER SEPARATOR STRAINER 4
WARNING
q Engine is at high temperature immediately after the machine has been operated. Wait for engine to
cool down before replacing the filter.
q Do not bring fire or sparks near the fuel.
2. Prepare a container to catch the drained fuel and set it
under the water separator.
3. Loosen drain valve (1) at the bottom of the water separator

and drain the fuel into the container.
4. Loosen ring nut (2), then remove cup (3).

5. Remove strainer (4) from the separator base.
6. Wash the interior of strainer (4) and cup (3) with clean fuel.
7. Check strainer (4) and replace it if it is damaged.

8. Clean the separator base and wash strainer (4), then install
the strainer to the separator base.
9. Coat the threaded portion of ring nut (2) thinly with grease.
10. Fill cup (3) with clean fuel, install it to the separator base,
then tighten it with ring nut (2).
The specified tightening torque of ring nut (2):
37 to 43 N·m (3.8 to 4.4 kgf·m, 27.5 to 31.8 lbft)
If the ring is loose, it will cause leakage of fuel, so always

tighten it to the specified torque.
REMARK
Be careful not to lose the O-ring, float, or spring. Be sure to assemble them after washing.
11. After installing filter cup (3), bleed air in the following manner.
12. Loosen air bleed plug (5) of the fuel filter.
13. Loosen the knob of feed pump (6), then pump it up and
down until no more bubbles come out with the fuel from air
bleed plug (5).
14. After bleeding the air, tighten air bleed plug (5), then push
in the knob of priming pump (6) and tighten it.
Tightening torque for air bleed plug: 7.8 to 11.8 N·m (0.8 to
1.2 kgf·m, 5.8 to 8.7 lbft)
4-50

Maintenance for every 50, 100, 250 and 500 hours service should be carried out at the same time.
CHANGE OIL IN TRANSFER CASE 4
WARNING
q Refill capacity: 6.5 liters (1.72 US gal)
1. Set a container to catch the oil under drain plug (P), then
remove drain plug (P) and drain the oil.
To prevent the oil from pouring out suddenly, loosen drain

plug (P) and remove it gradually.
2. After draining the oil, install drain plug (P).

3. Loosen bolt (1), remove cover (2), then take out strainer
(3).
4. Remove any dirt stuck to strainer (3), then wash it with

clean diesel oil or flushing oil. If the strainer is damaged,
replace it with a new part.
5. Replace O-ring (4) of cover (2) with a new part, then install.

7. After filling with oil, check that the oil is at the specified
level. For details, see “CHECK OIL LEVEL IN TRANSFER
CASE, ADD OIL (4-26)“.
8. Check that there is no oil leakage from the transfer case.
4-51
CLEAN TRANSFER CASE BREATHER 4
2. Remove the mud and dirt from around the breather (2),
then remove breather (2).
After removing the breather, take steps to prevent dirt or

dust from entering the mount.
3. Soak the breather (2) in washing liquid and wash it.
4-52
REPLACE HST OIL FILTER ELEMENT 4
WARNING
2. Using a filter wrench, turn filter cartridge (2) to the left to

remove it.
3. Install the new filter cartridge.

Tightening torque: 29 to 39 N·m (3.0 to 4.0 kgf·m, 21.7 to
28.9 lbft)
4. Run the engine at low idling for 5 minutes to bleed the air
from the HST circuit.
5. Check that the hydraulic oil is at the specified level. For

details, see “CHECK OIL LEVEL IN HYDRAULIC TANK,
ADD OIL (4-41)“.
6. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 to 5 times.
Be careful not to operate the cylinder to the end of its stroke (stop approx.100 mm (3.9 in) before the end of
stroke).
NOTICE
If the engine is run immediately at high speed or the cylinder is operated to the end of its stroke, the air
inside the cylinder will cause damage to the piston packing.
7. Next, operate the steering, bucket, and lift arm cylinders to the end of their stroke 3 to 4 times, then stop the
engine and loosen fillercap to bleed the air from the hydraulic tank.
8. Check that the hydraulic oil is at the specified level. For details, see “CHECK OIL LEVEL IN HYDRAULIC
TANK, ADD OIL (4-41)“.
9. After completing the air bleed operation, install cover (1).
Replace the HST filter element if the HST oil filter clogging warning pilot lamp lights up, even if 1000 hours or 1
year has not passed.
4-53
LUBRICATING 4
1. Using a grease pump, pump in grease through the grease fittings marked by the arrows.
2. After greasing, wipe off any old grease that was pushed out.
(1) Center hinge pin (2 places)
(2) Engine stop solenoid linkage (1 place)
CHECK TIGHTENING PARTS OF TURBOCHARGER 4

Please contact your Komatsu distributor to have the tightening portions checked.
CHECK PLAY OF TURBOCHARGER ROTOR 4

Please contact your Komatsu distributor to have the rotor play checked.
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT 4

Since inspection and replacement of the fan belt require special tools, contact your Komatsu distributor.
REMARK
The machine is equipped with an auto tensioner, so there is no need to adjust the tension.
If the alternator drive belt is in the following condition, the belt

must be replaced. Please ask your Komatsu distributor to
replace the belt.
q When horizontal scratch (1) crosses vertical scratch (2)
q When there are tears (3) in part of the belt

In case (4) where there are horizontal scratches only, there is
no need to replace the belt.
4-54

Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time.
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT 4
WARNING
q Refill capacity: 89 liters (25.51 US gal)
1. Lower the bucket horizontally to the ground and apply the parking brake, then stop the engine.
2. Remove covers (1) and (2).
3. Keep grip (3) pulled, then turn oil filler cap (F) counter-
clockwise and remove it.
4. Set a container to catch the oil under drain plug (P).
5. After removing drain plug (P), open drain valve (4) and
drain the oil.
6. After draining the oil, close drain valve (4) and install drain
plug (P).
7. Using a filter wrench, turn cartridge (5) to the left to remove

it.
8. Clean the filter holder, fill the new filter cartridge with oil,
then coat the seal and thread of the filter cartridge with oil
(or coat thinly with grease) and install.
When installing the seal, tighten it until its surface comes to

contact with the filter holder, then tighten it 1/3 turn more.
10. Check that the hydraulic oil is at the specified level. For
details, see “CHECK OIL LEVEL IN HYDRAULIC TANK,
ADD OIL (4-41)“.
11. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 to 5 times.
Be careful not to operate the cylinder to the end of its stroke (stop approx.100 mm (3.9 in) before the end of
stroke).
NOTICE
If the engine is run immediately at high speed or the cylinder is operated to the end of its stroke, the air
inside the cylinder will cause damage to the piston packing.
12. Next, operate the steering, bucket, and lift arm cylinders to the end of their stroke 3 to 4 times, then stop the
engine and loosen fillercap to bleed the air from the hydraulic tank.
4-55
13. Check the hydraulic oil level and add oil to the specified level. For details, see “CHECK OIL LEVEL IN
HYDRAULIC TANK, ADD OIL (4-41)“.
14. Next, raise the engine speed and follow the procedure in Step 12 to bleed the air. Repeat this process until no
more air comes out.
15. After completing the air bleed operation, install cover (1) and (2).
REPLACE HYDRAULIC TANK BREATHER ELEMENT 4
WARNING
2. Loosen bolt (2) at the top of the filler cap, then remove cap
cover (3).
3. Remove element (4).
4. Coat O-ring (5) of the new element with grease, then

install.
5. Align cap cover (3) with the grooves in the body, then
tighten with bolt (2).
6. Install cover (1).
4-56
CLEANING THE STRAINER OF THE BRAKE FILTER 4
WARNING
q After the motor is switched off, the parts and oil is very hot and can cause serious burns. Let it cool
down before you start working.
q Press the brake pedal approx. 15 times to reduce the pressure in the brake accumulators.
1. Press the brake pedal approx. 15 times to reduce the pres-

sure in the brake accumulators.
2. Open the hydraulic tank slowly to reduce the inner pres-

sure.
3. On the left side of the rear frame, unscrew the cover that is
located under the cab.
4. Place a container under the brake filter.

5. Unscrew the hydraulic hose (1) and the flange (2).
6. Take the strainer (3) out of the housing (4) and clean it with
clean diesel fuel.
7. Insert the strainer (3) into the housing (4). Make sure that
the side with the O-ring faces forward.
8. Screw the flange (2) back on and tighten it.
9. Screw the hydraulic hose back on (1) and tighten it.
10. Wipe away any hydraulic oil that might have leaked out.
11. Start the motor and let it run until the brake accumulator is
full. Switch off the motor.
12. Check the level of the hydraulic oil. Refill if required.
13. Bleed the hydraulic system and close the hydraulic tank.
14. Screw the cover back on.
4-57
CHANGE AXLE OIL 4
WARNING
q When changing the oil, apply the parking brake and secure the front and rear frames with the safety
bar.
q After the engine is stopped, the parts and oil are at high temperature, and may cause burns. Wait for
the temperature to go down before starting the operation.
q When the plug is removed, oil may spurt out, so turn it slowly to release the internal pressure, then
remove it carefully.
q Refill capacity (front and rear, each): 24.0 liters (6.34 US gal)
q A: Front B: Rear
1. Set a container to catch the oil under drain plug (P).
2. Remove plug (1), then remove drain plug (P) to drain the
oil.
REMARK
Remove the mud and dirt from around plug (1), then remove
the plug.
3. After draining the oil, clean drain plug (P) and install it
again.
4. Add axle oil through plug hole (1) at the refill level.
REMARK
For axles with ASD (Limited-Slip Differential), the brand of lubricating oil is different, so always use the specified
lubricating oil.
5. After adding oil, check that the oil is at the specified level. For details, see “CHECK AXLE OIL LEVEL, ADD
OIL (4-27)“.
REMARK
For operations where the brake is used frequently, change the axle oil at shorter intervals.
4-58
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR

FILTER 4
Remove both the recircuration air filter and fresh air filter in the same way as when cleaning, and replace them
with new parts.
For details of cleaning the recircuration air filter, see “CLEAN ELEMENT IN AIR CONDITIONER RECIRCULA-
TION FILTER (4-46)“.
For details of cleaning the fresh air filter, see “CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER (4-
40)“.
CHECK ALTERNATOR, STARTING MOTOR 4

The brush may be worn or have no grease on the bearing, so contact your Komatsu distributor for inspection or
repair.
If the engine is started frequently, carry out inspection every 1000 hours.
CHECK ENGINE VALVE CLEARANCE, ADJUST 4

As special tool is required for removing and adjusting the parts, request your Komatsu distributor for service.
CHECK BRAKE DISC WEAR 4
WARNING
q When checking the brake disc wear, apply the parking brake and secure the front and rear frames with
the safety bar.
q Make sure that the brake oil temperature is less than 60°C (140°F) before checking the brake wear.
q If the disc is near the wear limit, carry out inspection at shorter intervals, regardless of the specified
inspection interval.
When checking the brake disc for wear, there are 4 places (front axle and rear axle, left and right), so use the
same procedure to check all 4 places.
1. Remove cap nut (1).
4-59
2. Depress the brake pedal, keep it depressed, and push in

the rod (2) of the gauge until contacts the piston.
3. Wear (A) is the amount that end face (C) of rod (2) is pro-
truding from end face (D) of guide (3). Measure the
amount of protrusion.
The point where groove (E) of the rod is level with end face
(D) of the guide is permissible limit (B) for the disc wear.
If this point has been reached, please ask your Komatsu

distributor to carry out inspection and replacement of the
parts.
q If the disc is near the wear limit, carry out inspection at

shorter intervals, regardless of the specified inspection
interval.
4. Install cap nut (1).

to 28.9 lbft)
REMARK
On new machines, the position of the guide is adjusted so that the end face of rod (2) comes to the end face of
guide (3). For this reason, do not loosen locknut (4) except when replacing the disc.
Carry out the operation with two workers: one worker depresses the brake pedal and the other worker pushes in
rod (2).
CLEAN AND CHECK TURBOCHARGER 4

If there is carbon or oil sludge stuck to the blower impeller, it will lower the performance of the turbocharger or
cause it to break, so ask your Komatsu distributor to carry out the cleaning.
CHECK ACCUMULATOR GAS PRESSURE 4

When carrying out the EVERY 2000 HOURS SERVICE or EVERY YEAR SERVICE or when making periodic
replacement of the critical safety parts, please ask your Komatsu distributor to check the accumulator gas pres-
sure.
CHECK VIBRATION DAMPER 4

Check that there are no cracks or peeling in the outside surface of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.
4-60

Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time.
LUBRICATING 4
1. Using a grease pump, pump in grease through the grease fittings marked by the arrows.
2. After greasing, wipe off any old grease that was pushed out.
(1) Front drive shaft (2 places)
(2) Rear drive shaft (2 places)
(3) Drive shaft spline (1 place)
CHECK WATER PUMP 4

Check that there is no play in the pulley or any grease leakage, water leakage, or clogging of the drain hole. If any
abnormality is found, contact your Komatsu distributor for disassembly and repair or replacement.
4-61
4-62
TECHNICAL DATA
15
TECHNICAL DATA TECHNICAL DATA
TECHNICAL DATA 5
Item Unit
Operating weight (including 1 operator: 75 kg)
kg 14.220
(with bolt on cutting edge)
Normal load kg 4.480
3
Bucket capacity Heaped m 2,7
Engine model - Komatsu SAA6D102E diesel engine
Flywheel horsepower kW (HP)/rpm 124 (169)/2000
A Overall length mm 7.475
B Overall height mm 3.200
C Max. dimension when shaking bucket mm 5.260
D Overall width mm 2.525
E Min. ground clearance mm 440
F Bucket width mm 2.740
G Clearance Cutting edge [BOC tip] mm 2.855
H Reach Cutting edge [BOC tip] mm 990
I Dump angle degrees 45
Out of chassis mm 6.085
Min. turning radius
Center of outside tire mm 5.475
1st km/h 4,0 to 13,0
2nd km/h 13,0
Forward
3rd km/h 18,0
4th km/h 38,0
Travel speed
1st km/h 4,0 to 13,0
2nd km/h 13,0
Reverse
3rd km/h 18,0
4th km/h 38,0
Lift circuit
Hydraulic pressure Tilt circuit bar 210
Third control circuit
5-2
TECHNICAL DATA TECHNICAL DATA
5-3
NOISE EMISSION LEVELS TECHNICAL DATA
NOISE EMISSION LEVELS
Two signs are attached to the machine that state the noise
level produced.
In accordance with guideline ISO 6396, the value for the sound
pressure level measures is LpA = 72 dB/A.
In accordance with EC Directive 2000/14/EC, the guaranteed
value for the sound power level measures is LWA = 106 dB/A.
No alterations may be made to the machine which could have

an influence on the noise emission levels.
VIBRATION LEVEL
When used for its intended purpose, levels of vibration for the
earthworking machine transmitted from the operator's seat are
lower or equal to the test vibrations for the relative machinery
class in compliance with ISO 7096. The actual accelaration
value of the upper limbs is less than 2.5 m/s². The actual accel-
eration value for the body is less than 0.5 m/s². These values
were determined using a representative machine and with the
help of the measurement procedures that are defined in the
directives ISO 2631/1 and ISO 5349.
5-4
ATTACHMENTS, OPTIONS
16
SELECTING BUCKET AND TIRES ATTACHMENTS, OPTIONS
SELECTING BUCKET AND TIRES 6

Select the most suitable bucket and tires for the type of work and the ground conditions on the jobsite.
Type of work Bucket Ground conditions Tire

Stockpile bucket General ground conditions 20.5-25-12PR (L3 Rock)
Loading and carry-
(with bolt-on cutting edge) Leveled ground 20.5-25-12PR (L2 Traction)
ing products
2.8 m3 (3.7 cu.yd) Soft ground 20.5-25-12PR (L2 Traction)
Excavating bucket General ground conditions 20.5-25-12PR (L3 Rock)
Loading products
(with bolt-on cutting edge)
and crushed rock Hard ground 20.5-25-12PR (L3 Rock)
2.2 m3 (2.9 cu.yd)
BOC indicates a bolt-on type cutting edge.
When installing optional tires, please contact your Komatsu distributor.
6-2
ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER
MACHINE MONITOR WITH LOAD METER 6
(1) Machine monitor (4) Load meter cancel switch
(2) Monitor panel mode selector switch 1 (5) Load meter subtotal switch
(3) Monitor panel mode selector switch 2
MACHINE MONITOR 6
For details of the method of handling machine monitor (1), see

Section “MACHINE MONITOR (6-6)“.
6-3
MACHINE MONITOR WITH LOAD METER ATTACHMENTS, OPTIONS
MONITOR PANEL MODE SELECTOR SWITCH 1 6

display.
nal position.
Position ( ):
Press here to select (confirm) each mode or operation
Position ():
Press here to cancel each mode or operation
MONITOR PANEL MODE SELECTOR SWITCH 2 6

display.

nal position.
Position (>): Press here to go on to the next screen, or to move

the cursor forward, or to increase the number when entering
numerals
Position (<): Press here to go back to the previous screen, or to move the cursor back, or to reduce the number
LOAD METER CANCEL SWITCH 6
When the measured data is not needed, press switch (4) at the
top of the bucket control lever.
The data that has just been calculated will be canceled and the
display will return to the display before measuring.
6-4
LOAD METER SUB TOTAL SWITCH 6
Press switch (5) at the side of the bucket control lever to set the
TOTAL LOADED display (when in addition mode) or REMAIN-
ING TARGET display (when in remain mode) to 0.
6-5
MACHINE MONITOR 6
(A) Character display (E) Pilot display
(B) Emergency stop items (F) Meter display
(C) Caution items (G) Central warning lamp
(D) Inspection and maintenance items
MONITOR SYSTEM 6
TESTING ACTUATION OF MACHINE MONITOR SYSTEM
NOTICE
When the starting switch is in the ON position before start-
ing the engine, lamps (1) in the diagram on the right light
up for approx. 3 seconds and the alarm buzzer sounds for
approx. 3 seconds.
After 3 seconds all lamps except lamps (2) go out.
Lamps (2) go out after the engine starts.
If any lamps do not light up there is probably a failure or a
disconnection, so please ask your Komatsu distributor to
carry out inspection.
When the starting switch is turned ON, if the directional lever is

not at the neutral position, the central warning lamp lights up
and the alarm buzzer sounds intermittently. If this happens,
return the directional lever to the neutral position. The lamp will
go out and the buzzer will stop.
6-6
TYPES OF WARNING 6
If an abnormality occurs on the machine, or if any switch or

lever is operated accidently, the monitor display and buzzer
give a warning to inform the operator.
Following are the types of warning depending on the level of

danger.
REMARK
For details of action codes “E03“ to “E00“, see “ACTION CODE
DISPLAY (6-9)“.
EMERGENCY STOP
This warning is given if there is a serious failure that affects the normal operation of the machine or if the setting is
incorrect.
The central warning lamp on the monitor and the caution lamp for the location of the abnormality light up, and at
the same time, the alarm buzzer sounds and action code “E03“ is displayed on character display (1).
CAUTION
This warning is given if the cooling water or lubricating oil overheat.

The central warning lamp on the monitor and the individual caution lamps light up, and at the same time, the alarm
buzzer sounds and action code “E02“ is displayed on character display (1).
MISTAKEN OPERATION
This warning is given if any switch or lever is operated mistakenly.
The central warning lamp on the monitor lights up and the alarm buzzer sounds at the same time. In addition, if
the travel speed is too high, action code “E00“ is displayed on character display (1).
INSPECTION AND MAINTENANCE
This warning is given if it is necessary to carry out inspection and maintenance of wear parts, or if it is necessary to
check the oil or cooling water level.
The individual caution lamp on the monitor lights up, and at the same time, action code “E01“ is displayed on
character display (1).
In the case of this warning, the central warning lamp does not light up and the alarm buzzer does not sound.
CENTRAL WARNING LAMP 6
This display portion (1) lights up if any emergency stop item,

caution item, or mistaken operation of any switch or lever
occurs. At the same time, the alarm buzzer sounds.
Check the content of the display and carry out the specified
action for the item.
6-7
CHARACTER DISPLAY PORTION 6
(1) Service meter (4) Failure code display

(2) Clock (5) Filter, oil replacement time display
(3) Action code display
Normally, the service meter is displayed on the character display.
If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out
inspection and maintenance, an action code is displayed to recommend suitable action.
When the time for replacing the filter or changing the oil is reached, after completion of the system check with the
starting switch at the ON position, the maintenance monitor caution lamps flash or light up, and at the same time,
the filter or oil to be replaced is displayed.
NOTICE
Information regarding the failure of the machine or maintenance is displayed on the character display
when the starting switch is at the ON position, check the display to confirm that there is no abnormality
before starting to travel.
6-8
SERVICE METER
This meter (1) shows the total time that the machine has been
operating.
While the engine is running, the service meter advances even if

the machine is not moving.
The meter advances by 1 for every hour of operation, regard-

less of the engine speed.
Even if the starting switch is at the OFF position, the service

meter will display as long as the top part ( ) of monitor panel
mode selector switch 1 is being pressed.
NOTICE
When the starting switch is at the OFF position, if the service meter is displayed even though the top ( )
of monitor panel mode selector switch 1 is not being pressed, there is probably a failure in the machine,
so please contact your Komatsu distributor for inspection.
CLOCK
This display portion (2) shows the time.
For details of the method of adjusting the time, see “METHOD

OF SETTING TIME ON CLOCK (6-46)“.
Even when the starting switch is at the OFF position, the time
is displayed while the top ( ) position of monitor panel mode
selector switch 1 is being pressed.
ACTION CODE DISPLAY
WARNING
If action code E03 is displayed, stop the machine immediately and check the failure code. For details, see
“FAILURE CODE DISPLAY (6-11)“.
Inform your Komatsu distributor of the failure code and ask for repairs.
If there is a failure on the machine, or it is necessary to change the method of operation, or if inspection or mainte-
nance must be carried out, action code E00, E01, E02, or E03 is displayed on the character display in display por-
tion (3).
If different failures occur at the same time, the action code for the more serious problem is displayed.
The level of seriousness is as follows, starting with the most serious: E03, E02, E01, E00.
In the case of action codes E00, E02, and E03, the alarm buzzer sounds intermittently and the central warning
lamp lights up.
If action codes E00, E01, E02, or E03 are displayed on the character display, stop operations, check the content
of the display, and take the following action.
6-9
E03: When this code is displayed, stop the machine immedi-

ately, check the failure code, and contact your Komatsu distrib-
utor for repairs.
REMARK
The top line of the character display displays “E03“ and the bot-
tom line displays “CHECK RIGHT NOW“ and “CALL“ in turn for
3 seconds each.
The telephone number is displayed on the right of the “CALL“
display. If the telephone number has not been set, there is a
blank. For details of the method of setting the telephone num-
ber, see “INPUT METHOD FOR TELEPHONE NUMBER (6-
53)“.
E02: If overrun related information is displayed, reduce the

engine speed and the speed of the machine while continuing
operations.
If the overheat related display is given, stop the machine and
run the engine under no load at a mid-range speed.
If an action code is still displayed after doing this, check the fail-
ure code and contact your Komatsu distributor for repairs.
REMARK
tom line displays the condition of the machine related to over-
heating.
E01: When a failure occurs in the mechanical system, such as

a drop in the level of the engine cooling water, the maintenance
location is displayed. If the maintenance caution lamp lights up
at the same time, carry out inspection and maintenance of the
item indicated after completion of the day's work or when
changing shifts. If “MAINTENANCE“ is displayed together with
E01, check the failure code and ask for repairs to be carried
out.
REMARK
“E01“ is displayed on the top line of the character display and
“MAINTENANCE“ or the part of the machine requiring inspec-
tion, filling of fluid, or replacement is displayed on the bottom
line.
6-10
E00: If travel speed overrun is displayed, ease the accelerator

pedal back to reduce speed.
REMARK
tom line displays “OVERRUN PROTECT“.
FAILURE CODE DISPLAY
If an action code is displayed on the character display, check the failure code according to the failure code display
method given below.
When contacting your Komatsu distributor to request repairs, please inform your distributor of the failure code.
Method of displaying failure code
1. If an action code is displayed on the character display of

display portion (4), press the top (>) of monitor panel mode
selector switch 2 (A).
The action code will change to the failure code.
q The failure code is displayed with the first 6 digits on

the left of the top line of the character display.
q The code displayed after the space on the right side of

the failure code indicates the controller that detected
the failure code.
q The component causing the failure is displayed on the

bottom line of the character display.
Top right code Controller detecting failure code

MON Machine monitor
HST HST controller
2. Press the top (>) of monitor panel mode selector switch 2 (A) again.
If the condition is normal, the service meter is displayed for several seconds, then the display returns to the
action code.
If more than one failure has occurred at the same time, the next failure code is displayed.
6-11
FILTER, OIL REPLACEMENT TIME DISPLAY
After completion of the system check and when the starting

switch is in the ON position, if any filter or oil item is approach-
ing the replacement time, this display (5) shows the item for
approx. 30 seconds. When this happens, the maintenance
caution lamp also flashes or lights up.
After replacing the filter or changing the oil, reset the time for
replacement. For details, see “RESET METHOD FOR FIL-
TER, OIL REPLACEMENT TIME (6-52)“.
REMARK
The top line of the character display shows the ID No. and item name for the item needing replacement; the bot-
tom line shows the time remaining until replacement and the total number of times the replacement has been car-
ried out.
If the replacement time has already passed, a minus (-) sign appears before the time.
After the display has been given for 30 seconds, it does not appear again until the starting switch is turned to the
ON position.
The message in the illustration above is not shown on the character display if an action code is being displayed.
If there are two or more items to be displayed, the display changes repeatedly every three seconds. If there are
more than 10 items, all the items are displayed once each, then the display returns to the normal display.
The display appears when there is 30 hours remaining until the filter or oil replacement time. If the replacement
time has passed, a minus (-) sign appears before the time for the first 30 hours. When more than 30 hours have
passed, the display is no longer given.
The maintenance caution lamp flashes as the replacement time approaches, and after the replacement time has
passed, it lights up.
Items for display of filter, oil replacement time
Item Replacement interval (H) Character display ID number

Engine oil 500 ENG OIL 01
Engine oil filter 500 ENG FILT 02
Fuel filter 500 FUEL FILT 03
Transfer oil 1000 TRANSF OIL 25
HST oil filter 1000 HST FILT 26
Hydraulic filter 2000 HYD FILT 04
Hydraulic oil 2000 HYD OIL 10
Axle oil 2000 AXLE OIL 15
6-12
REMARK
See the section below for details of the procedure for replacing the filter and oil.
Engine oil
Engine oil filter

Fuel filter
“REPLACE FUEL FILTER CARTRIDGE (4-49)“
Transfer oil
“CHANGE OIL IN TRANSFER CASE (4-51)“
HST oil filter

“REPLACE HST OIL FILTER ELEMENT (4-53)“
Hydraulic filter
Hydraulic oil
Axle oil
“CHANGE AXLE OIL (4-58)“
6-13
EMERGENCY STOP ITEM 6
CAUTION
If these lamps light up and the buzzer sounds, stop operations immediately and carry out inspection and
maintenance of the applicable location.
If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the lamp
for the location of the abnormality and the central warning lamp will light up.
At the same time, the top line of the character display displays “E03“ and the bottom line displays “CHECK RIGHT
NOW“ and “CALL“ alternately for 3 seconds each, so stop the machine immediately in a safe place, stop the
engine, and carry out inspection.
(1) Brake oil pressure caution lamp (3) Battery charge circuit caution lamp
(2) Engine oil pressure caution lamp (4) Steering oil pressure caution lamp
6-14
BRAKE OIL PRESSURE CAUTION LAMP
This lamp (1) lights up when the brake oil pressure goes below
the specified value.

If the brake oil pressure goes down during operation, the brake oil pressure caution lamp and central warning
lamp light up and the alarm buzzer sounds intermittently.
If the brake oil pressure caution lamp lights up, the footbrake may not work, so keep the parking brake applied to
prevent the machine from moving.
Keep the parking brake applied to prevent the machine from moving until the brake pressure becomes normal and
the brake oil pressure caution lamp goes out.
ENGINE OIL PRESSURE CAUTION LAMP
lubricating oil pressure has dropped.

If the engine lubricating oil pressure goes down during operation, the engine lubricating oil pressure caution lamp
and central warning lamp light up and the alarm buzzer sounds intermittently.
6-15
BATTERY CHARGE CIRCUIT CAUTION LAMP
This lamp (3) lights up when the engine is running to warn the
operator that an abnormality has occurrred in the charging cir-
cuit.

If an abnormality occurrs in the charging circuit during opera-

tion, the battery charge circuit caution lamp and central warn-
ing lamp light up and the alarm buzzer sounds intermittently.
STEERING OIL PRESSURE CAUTION LAMP
(Red)
This lamp (4) lights up to warn the operator that the steering oil
pressure has dropped.

If the steering oil pressure goes down during operation, the

steering oil pressure caution lamp and central warning lamp
light up and the alarm buzzer sounds intermittently.
6-16
CAUTION ITEMS 6
CAUTION
(1) Axle oil temperature caution lamp (4) Engine cooling water temperature caution lamp
(2) Parking brake reminder caution lamp (5) Fuel level caution lamp
(3) HST oil temperature caution lamp
AXLE OIL TEMPERATURE CAUTION LAMP
This lamp (1) lights up to warn the operator that the brake oil

In continuous heavy-duty operations or when traveling long distances downhill where the brake is used frequently,
the axle oil temperature becomes high, so the axle oil temperature caution lamp and central warning lamp light up
and the alarm buzzer sounds intermittently.
At the same time, the top line of the character display displays “E02“ and the bottom line displays “BRAKE OVER-
HEAT“, so take the following action.
1. Release the accelerator pedal and move the speed range selector switch down one range to reduce the travel
speed.
2. Avoid using the brake.
6-17
3. Do not keep the brake pedal depressed continuously; use

the brake only intermittently.
If use of the brake is reduced for a short time in the way recommended above, the axle oil temperature will go
down and the caution lamp will go out.
PARKING BRAKE REMINDER CAUTION LAMP
This lamp (2) lights up when engine is stopped but the parking
brake is not applied.
At the same time, the central warning lamp lights up and the
When the parking brake is applied, the lamp goes out and the
buzzer stops.
HST OIL TEMPERATURE CAUTION LAMP
This lamp (3) lights up to warn the operator that the HST oil

When the HST oil temperature goes up, the HST oil temperature caution lamp and central warning lamp light up,
and the alarm buzzer sounds intermittently.
At the same time, the top line of the character display displays “E02“ and the bottom line displays “HST OIL
OVERHEAT“, so take the following action.
ENGINE COOLING WATER TEMPERATURE CAUTION LAMP
cooling water temperature has risen.

If the engine cooling water temperature rises, the engine cooling water temperature caution lamp only will light up.
If the water temperature rises further, the central warning lamp will light up and the alarm buzzer will sound inter-
mittently.
At the same time as the central warning lamp lights up, the top line of the character display displays “E02“ and the
bottom line displays “BRAKE OVERHEAT“, so stop the machine and run the engine under no load at a mid-range
speed until the lamp goes out.
6-18
FUEL LEVEL CAUTION LAMP
This lamp (5) lights up if the amount of fuel remaining in the

fuel tank goes below 31 liters (8.19 US gal).
If it lights up, check and add fuel as soon as possible.
REMARK
Even if the caution lamp lights up, action code “E02“ is not dis-
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED 6
When the travel speed goes above 40.0 km/h (24.9 MPH), the
central warning lamp lights up and the alarm buzzer sounds.
At the same time, the top line of the character display displays
“E00“ and the bottom line displays “OVERRUN PROTECT“.
If the alarm buzzer sounds, let the accelerator pedal back to

reduce speed.
TRAVEL SPEED LIMIT FUNCTION

The travel speed is automatically controlled so that it does not go above approx. 42 km/h (26.1 MPH).
6-19
INSPECTION AND MAINTENANCE ITEM 6
CAUTION
(1) Radiator coolant level caution lamp (4) HST oil filter clogging caution lamp
(2) Engine oil level caution lamp (5) Air cleaner clogging caution lamp
(3) Maintenance caution lamp
RADIATOR COOLANT LEVEL CAUTION LAMP
This lamp (1) lights up to warn the operator that the coolant
level in the radiator has gone down.

monitor lights up if the coolant level in the radiator is low.
“E01“ and the bottom line displays “COOLANT LOW“, so check
the water level in the radiator and add water.
If the coolant level in the radiator becomes too low, the radiator coolant level caution lamp will light up.
At the same time, the top line of the character display displays “E01“ and the bottom line displays “COOLANT
LOW“, so stop the engine, check the water level in the radiator, and add water.
6-20
ENGINE OIL LEVEL CAUTION LAMP
This lamp (2) lights up to warn the operator that the oil level in
the engine oil pan has gone down.

monitor lights up if the oil level in the engine oil pan is low.
“E01“ and the bottom line displays “ENG OIL LEVEL LOW“, so
do not start the engine. Check the oil level in the engine oil pan
and add oil.
REMARK
During checks before starting, if the engine is started with the engine oil level caution lamp lighted up, the lamp
will stay lighted up.
Stop the engine, check the oil level in the engine oil pan, and add oil.
The engine oil level cannot be checked while the engine is running.
MAINTENANCE CAUTION LAMP
CAUTION
If the caution lamp lights up, repair the problem as soon as possible. If this is left as it is, it will lead to fail-
ure.
When the time for oil change is reached, this lamp (3) flashes
or lights up for approx. 30 seconds after completion of the sys-
tem check when the starting switch is at the ON position.
REMARK
The maintenance caution lamp flashes when there is less than
30 hours to the replacement time, and after the replacement
time has passed, it stay on.
For details of the items covered by filter and oil replacement, see “FILTER, OIL REPLACEMENT TIME DISPLAY
(6-12)“.
After replacing the filter or changing the oil, reset time for the replacement. For details, see “RESET METHOD
FOR FILTER, OIL REPLACEMENT TIME (6-52)“.
6-21
HST OIL FILTER CLOGGING CAUTION LAMP
When the engine is running, this lamp (4) lights up if the HST
oil filter is clogged.

This lamp lights up if the HST oil filter is clogged.

At the same time, the top line of the character display displays “E01“ and the bottom line displays “HST OIL FIL-
TER“, so replace the oil filter.
REMARK
The lamp may light up in cold temperatures, but it should go out when the HST oil temperature gauge indicator
enters the white range.
AIR CLEANER CLOGGING CAUTION LAMP
This lamp (5) lights up if the air cleaner element becomes

clogged when the engine is running.


The lamp lights up if the air cleaner element becomes clogged.
At the same time, the top line of the character display displays “E01“ and the bottom line displays “AIR FILTER“, so
stop the engine and clean or replace the element.
6-22
PILOT DISPLAY PORTION 6

When the starting switch is ON, the pilot display lights up when the display items are functioning.
(1) Parking brake pilot lamp (5) Pilot lamp for speed range selector switch position
(2) Preheating pilot lamp (6) Turn signal pilot lamp
(3) Emergency steering pilot lamp (7) Head lamp high beam pilot lamp
(4) Directional lever position pilot lamp
PARKING BRAKE PILOT LAMP
This lamp (1) lights up when the parking brake is applied.
PREHEATING PILOT LAMP
This lamp (2) lights up when the engine preheating electric

heater is actuated.
In cold weather, when the starting switch is turned to the ON

position, this lamp lights up, and when the preheating is com-
pleted, it goes out.
The preheating time differs according to the engine water tem-
perature.
6-23
EMERGENCY STEERING PILOT LAMP
(Green)
If this lamp (3) lights up when the engine is running or when the
machine is operating, it indicates that the condition is normal.
If it does not light up, an abnormality has occurred in the emer-

gency steering circuit.
Move the machine immediately to a safe place, stop the

engine, and check the condition.
DIRECTIONAL LEVER POSITION PILOT LAMP
This lamp (4) indicates the position of the directional lever.
PILOT LAMP FOR SPEED RANGE SELECTOR SWITCH POSITION
This lamp (5) indicates the position of the speed range selector
switch.
TURN SIGNAL PILOT LAMP
When the turn signal lamp flashes, this lamp (6) also flashes.
REMARK
If there is a disconnection in the turn signal lamp, the flashing
interval becomes shorter.
6-24
HEAD LAMP HIGH BEAM PILOT LAMP
This lamp (7) lights up when the head lamp is at high beam.
6-25
METER DISPLAY PORTION 6
(1) HST oil temperature gauge (3) Fuel gauge
(2) Engine coolant temperature gauge (4) Load meter
HST OIL TEMPERATURE GAUGE
This meter (1) indicates the HST oil temperature.

range (A).

lamp (C) inside the HST oil temperature gauge lights up. At the
same time, the central warning lamp lights up and the alarm
buzzer sounds.
In addition, the top line of the character display displays “E02“

and the bottom line displays “HST OVERHEAT“.
Run the engine at a midrange speed under no load and wait for the indicator to return to the white range (A).
ENGINE COOLING WATER TEMPERATURE GAUGE
This meter (2) indicates the engine coolant temperature.

range (A).

lamp (C) inside the engine coolant temperature gauge lights
up. At the same time, the central warning lamp lights up and
the alarm buzzer sounds.
In addition, the top line of the character display displays “E02“

and the bottom line displays “ENGINE OVERHEAT“.
Run the engine at a midrange speed under no load and wait for the indicator to return to the white range (A).
6-26
FUEL GAUGE
This meter (3) indicates the amount of fuel remaining in the fuel
tank.
If the indicator is at the F position, it indicates that the tank is

full.
If the indicator is at the E position, it indicates that there is little

fuel remaining. When the amount of remaining fuel goes below
31 liters (8.19 US gal), caution lamp (A) inside the fuel gauge
lights up.
If it lights up, check the fuel level and add fuel.
LOAD METER
For details of display portion (4), see Section “LOAD METER (6-28)“.
6-27
LOAD METER 6
LOAD METER FUNCTIONS
(1) Addition mode display (4) Bucket load display

(2) Remain mode display (5) Material type display
(3) TOTAL LOADED display (addition mode) or
(6) Speed display or engine speed display
REMAINING TARGET display (remain mode)
NOTICE
When using the load meter to measure, make sure that the
HST oil temperature gauge indicator is in white range (A)
before measuring.
Operation of the various functions of the load meter is carried out by using monitor panel mode selector switch 1
and monitor panel mode selector switch 2 together with the load meter cancel switch and load meter subtotal
switch on the bucket control lever.
There are the following two types of measurement methods in the load meter mode.
q Addition mode (measuring total amount loaded)
This method is useful for measuring the production, such as the amount loaded into the dump truck, the
amount loaded into the hopper, or the total work for half a day. The data can be displayed up to a maximum of
9999 tons for each type of work.
q Remain method (measuring amount remaining)
Use this method for work requiring a determined amount (prevention of overloading, mixing of different types
of material, etc.)
REMARK
The total load display or remaining load display (3) can be displayed up to a maximum of 999.9 tons when display-
ing one place of decimal (units of 100 kg). If the value exceeds 1000 tons, the decimal point display goes out and
the value is displayed in units of 1 ton.
6-28
LOAD METER ADDITION MODE
q For details of the method of switching to the addition mode,

see “SETTING ADDITION MODE (6-31)“.
q “TOTAL LOADED“ lights up on load meter display (1).
q The bucket load is displayed on load meter display (2), and

the total load is displayed on display (3).
q If the measured data is not needed, press load meter can-

cel switch (4).
The data for the last calculation is canceled and display (3)
returns to the display for the previous measurement.
q To return total load display (3) to 0, press load meter sub

total switch (5).
REMARK
All operations using the load meter can be carried out simply by using the addition mode.
If the target value is set and it is desired to display the remaining load, use the subtraction mode.
LOAD METER REMAIN MODE
q For details of the method of switching to the remain mode,

see “SETTING REMAIN MODE (6-33)“.
q “REMAINING TARGET“ lights up on load meter display (1).
q The bucket load is displayed on load meter display (2), and

the amount remaining to the target is displayed on display
(3).
q If the measured data is not needed, press load meter can-

cel switch (4).
The data for the last calculation is canceled and display (3)
returns to the display for the previous measurement.
q To return total load display (3) to 0, press load meter sub

total switch (5).
6-29
SELECTION OF DISPLAY FOR TYPE OF LOAD
q For details of the method of selecting the type of load, see

“SETTING ADDITION MODE (6-31)“ and “SETTING
REMAIN MODE (6-33)“.
q It is possible to make categories for a maximum of five

types of material for TOTAL LOADED or REMAINING
TARGET.
If the settings for types A to E are changed for each type of

material when operations are carried out, it is possible to
store in memory the data for TOTAL LOADED or REMAIN-
ING TARGET for each type of material.
q One of the selected types of material A to E is displayed on
load meter display (1).
METHOD OF CALIBRATION (ADJUSTING 0 POINT)

For details of the method of carrying out calibration, see “CARRYING OUT CALIBRATION (ADJUSTING 0 POINT)
WHEN EMPTY (6-39)“.
DELETING LOAD METER DISPLAY
q It is possible to set so that there is no load meter display.
If there is no display, only the speed is displayed.
q For details of the method of switching to display or non-display, see Section “STOPPING CALCULATION (6-
38)“.
SPEED DISPLAY
q The travel speed of the machine is displayed on load meter

display (1).
6-30
HANDLING LOAD METER DISPLAY
SETTING ADDITION MODE
When carrying out loading operations in the addition mode, refer to “ADDITION FUNCTION (6-41)“ after setting
the addition mode.
1. Check that the normal service meter and time are dis-
2. Press the ( ) of monitor panel selector switch 1 and dis-

play “LOAD METER“.

play “ADDITION MODE“.
REMARK
If the previous setting was the addition mode, “ADDITION
MODE“ is displayed; if the previous setting was the remain
mode, “REMAINS MODE“ is displayed.
6-31
4. If the display is “REMAINS MODE“, press the (>) or (<) of

monitor panel mode selector switch 2 to display “ADDI-
TION MODE“.

play “MATERIAL < > SELECT“.
6. Check the display for the selected material on load meter

display (1).
The present selection display is A.
In the case of the addition mode, “TOTAL LOADED“ is dis-

played on display (2).
7. If A is to remain selected, press the () of monitor panel

mode selector switch 1. A is then selected.
If A is to be changed to B to E, press the (>) or (<) of moni-

tor panel mode selector switch 2 to select the type of mate-
rial, then press the () of monitor panel mode selector
switch 1.
8. This completes the setting of the addition mode.

The character display returns to the normal service meter
and time display.
Once the setting has been made, even if the starting switch
is turned OFF and operations are stopped, the setting is
retained. When operations are started again, there is no
need to carry out the setting again. All further loads will be
added to the total load recorded before operations were
stopped.
6-32
SETTING REMAIN MODE
When carrying out operations in the remain mode, set to the remain mode. For details of the remain mode func-
tions, see “SUBTRACTION FUNCTION (6-43)“.


play “ADDITION MODE“.
REMARK
If the previous setting was the addition mode, “ADDITION
MODE“ is displayed; if the previous setting was the remain
mode, “REMAINS MODE“ is displayed.
6-33
4. If the display is “ADDITION MODE“, press the (>) or (<) of

monitor panel mode selector switch 2 to display “REMAIN
MODE“.

play “MATERIAL < > SELECT“.
6. Check the display for the selected material on load meter

display (1).
The present selection display is B.
In the remain mode, “REMAINING TARGET“ is displayed

on display (2).
7. If B is to remain selected, press the () of monitor panel

mode selector switch 1. B is then selected.
If B is to be changed to A, C, D or E, press the (>) or (<) of

monitor panel mode selector switch 2 to select the type of
material, then press the () of monitor panel mode selector
switch 1.

play “INPUT TARGET“.
9. Input the target load.
Before the target is input, “0000.0 t“ is displayed on the tar-

get line and the cursor is at the 1000 ton position.
The following explanation explains the procedure when inputting 30 tons as the target.
10. “0“ is marked by the cursor at the 1000 ton position, so leave it at “0“ and press the ( ) of monitor panel selec-
tor switch 1.
“0“ is selected and the cursor moves to the 100 ton position.
11. “0“ is marked by the cursor at the 100 ton position, so leave it at “0“ and press the ( ) of monitor panel selec-
tor switch 1.
6-34
12. The “0“ at the 10 ton position must be changed to “3“, so

press the (>) or (<) of monitor panel mode selector switch 2
to change to “3“, then press the ( ) of monitor panel selec-
tor switch 1.
13. “0“ is already displayed at both the 1 ton and 0.1 ton posi-
tions, so press the ( ) of monitor panel selector switch 1
twice.
“0.0“ is selected and 30 tons is set as the target load.
REMARK
If 0 tons is input as the target load, it is not accepted. The buzzer gives a long sound and the mode changes to
give the addition mode display.
14. This completes the setting of the remain mode.
The character display returns to the normal service meter

and time display.
Once the setting has been made, even if the starting switch
is turned OFF and operations are stopped, the setting is
retained. When operations are started again, there is no
need to carry out the setting again. All further loads will be
subtracted from the total load recorded before operations
were stopped.
6-35
TOTAL LOAD DATA DISPLAY

3. Press the ( ) of monitor panel selector switch 1, then

to display “DATA“.
4. Press the ( ) of monitor panel selector switch 1 to display

“TOTAL DATA“.
The time when the load on the bottom line was calculated
is displayed as the hour meter standard.

2 to select the data for each of A to E or the all lighted-up
display.
6-36
The total load data for each of A to E and for all data is dis-
played on the load meter display.
Check the material selection display on load meter display (1).
In the example on the right, all of A to E for all data selected
light up.
On display (2) the total load data for all data or individual total
load data for A to E is displayed.
On display (3) the individual number of loads for A to E is dis-

played.
The total value can be cleared as follows.

2, and select the individual items to be cleared from A to E
or select the all lighted-up display.
7. Press the ( ) of monitor panel selector switch 1 to display

“RESET“.
8. “YES < > NO“ is displayed, and the cursor is at the NO

position, so press the(<) of monitor panel mode selector
switch 2 to move the cursor to the “Y“ of YES.
9. Press the () of monitor panel mode selector switch 1.
The selected individual item from A to E or all the data is

cleared.
If the monitor accepts the clear command, the buzzer gives

short sounds and the display returns to the normal service
meter and time display.
6-37
STOPPING CALCULATION


and select “OFF“ on the bottom line.
4. Press the ( ) of monitor panel selector switch 1. The load

meter display goes out and the screen switches to the
speed display. In addition, the character display returns to
the normal service meter and time display.
5. When starting the calculation again, set to the addition
mode or remain mode. For details, see “SETTING ADDI-
TION MODE (6-31)“ or “SETTING REMAIN MODE (6-33)“.
6-38
CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY
REMARK
When carrying out calibration with the machine unloaded, the accuracy is improved by doing as follows.
Hydraulic oil temperature: Carry out the calibration with the hydraulic oil temperature in the normal operating range
(approx. 60 - 85°C (140 - 185°F), near the center of the white range on the hydraulic oil temperature gauge).
(Compensate for the error caused by the temperature of the pressure sensor. This makes it possible to carry out
calibration that matches the machine.)
Engine speed: When carrying out calibration, keep the engine speed constant at the speed used for normal oper-
ations (near the rated speed).
(The effect of compensation for the engine speed shows the maximum effect. When carrying out the actual mea-
surement, even if the engine speed varies, accurate measurement can be made.)
Bucket posture: Carry out calibration with the bucket at full tilt.
Carry out the measurement for the weight also at the full tilt. If the bucket is not at full tilt, the position of the center
of gravity of the load changes and the load cannot be measured accurately.
Work equipment speed: When carrying out calibration, operate the work equipment slowly. (Take approx. 10 sec-
onds to raise from the travel posture to the maximum height of the lift arm.)
(This is done in order to increase the measurement data when carrying out calibration.)


and select “CALIBRATION“.
6-39
4. Press the ( ) of monitor panel selector switch 1. “EMPTY

BUCKET“ is displayed on the bottom line.
5. Press the ( ) of monitor panel selector switch 1. The dis-

play changes to “STEP 1“ on the top line, and “FULLY
ROLL BACK“ and “AT CARRY POSI“ are displayed in turn
for 3 seconds each on the bottom line.
6. Follow the instructions on the screen, tilt the empty bucket

back fully, then lower the lift arm to set to the travel posture.
7. When the lift arm is lowered, the display changes to “STEP

2“ and “RAISE TO TOP“.
This completes preparation for setting the calibration when

empty.
8. Follow the instructions on the screen and raise the lift arm
fully.
When raising the lift arm, carry out the operation as close
to actual operation as possible.
9. When the setting of the empty calibration is completed cor-

rectly, the buzzer gives short sounds, and the character
display returns to the normal service meter and time dis-
play.
10. If the setting of the empty calibration is not completed cor-

rectly, the buzzer gives a long sound, and the display
returns to “CALIBRATION“ on the top line and “EMPTY
BUCKET“ on the bottom line.
11. Repeat the procedure again from Step 5.
6-40
CARRYING OUT CALIBRATION WHEN LOADED
Normally there is no need to carry out calibration with load. But in the following cases, installation of a bucket
except standard and replacement of main monitor, the pressure sensor of load meter or replacement of boom
angle sensor, accurate value can not be showed. In this case there is need to carry out calibration with load.
Please contact KOMATSU distributor to carry out the calibration.
ADDITION FUNCTION
After setting the addition mode, if the material being handled is

“A“ as shown in the diagram on the right, the procedure is as
follows.
1. Measure the 1st load
The result of weighing the bucket load is 5.1 ton.
The bucket load display shows 5.1 ton

The total load display shows 5.1 ton
Precautions when weighing load

q The suitable precision for the weight of the bucket load
can be obtained if the engine speed is slightly above
low idling.
q Set the bucket to the full tilt position.
q When starting the measurement, set the height of the lift arm within a range from the travel posture to -10°
from the horizontal position of the lift arm.
2. When 15 seconds have passed from the time of measure-

ment, the bucket load is canceled and the display returns
to 0.0.
6-41
REMARK
In the condition in Step 1 or Step 2, if the lift arm is lowered to
near the travel posture, then raised again to measure the
bucket load again, the load meter will recognize that work was
carried out for the second loading operation.
The bucket load display will show 5.1 ton
The total load display will show 10.2 ton (= 5.1 + 5.1)
In this condition, press the load meter cancel switch to return to
Step 2.
3. Measure the 2nd load
The result of weighing the 2nd bucket load is 4.9 ton.
The bucket load display shows 4.9 ton
The total load display shows 10.0 ton (= 5.1 + 4.9 ton)
4. When 15 seconds have passed from the time of measure-

ment, the bucket load is canceled and the display returns
to 0.0.
5. Repeat Steps 3 and 4 to weigh the 3rd and following loads.
6. To start the next loading operation, press the load meter

subtotal switch to complete the 1st loading operation.
6-42
7. The screen will return to the initial display.
REMARK
It may not be possible to measure the weight of the load when carrying out the following operations.
When the boom is not kept raised continuously for at least 1.5 sec.
When the boom is operated to RAISE continuously but the lifting speed is not constant
When the boom angle when starting the RAISE operation is near horizontal
If the result of the measurement is not displayed on the load meter, start the scooping operation with the bucket at
a low position (close to the ground surface), raise the boom at a constant speed, and keep the boom raised contin-
uously for at least 1.5 sec.
SUBTRACTION FUNCTION
The following explanation assumes that after setting the remain

mode, the target load is 12 tons as shown in the diagram on
the right and that B is selected as the type of material.
1. This is the first load.
The result of measuring the load in the bucket is 5.1 tons.
12.0 - 5.1 = 6.9, so the next target load is displayed as 6.9

tons.
2. When 15 seconds pass after measuring, the bucket load is

deleted and the load is displayed as 0.0 tons.
6-43
REMARK
In the condition in Step 1 or Step 2, if the lift arm is lowered to
near the travel posture, then raised again to measure the
bucket load again, the load meter will think that work was car-
ried out for the second loading operation.
The bucket load display will show 5.1 ton
The remaining load display will show 1.8ton (= 6.9 - 5.1)
In this condition, press the load meter cancel switch to return to
Step 2.
3. This is the second load.
The load in the bucket is 4.9 tons.
6.9 - 4.9 = 2.0 tons, so the next target load is displayed as

2.0 tons.
4. This is the third load.
The result of measuring the load in the bucket is 5.0 tons.
This is 3.0 tons over the target amount, so -3.0 tons is dis-
played.
5. The target load is displayed as -3.0 tons, and after 3 sec-

onds, the display changes to the display shown on the
right.
The target value of 2.0 tons is the target load after complet-
ing the loading of the second bucket.
6. Load the target of 2.0 tons from the 5.0 tons loaded in the
bucket.
When this is done, “2.0“ flashes for the target load.
7. After loading, lower the lift arm and then raise it again in
order to weigh the amount remaining in the bucket. The
amount remaining in the bucket is weighed and displayed.
6-44
The amount remaining in the bucket is 3.5 tons.

The target load is 2.0 - (5.0 - 3.5) = 0.5 tons
The next target load of 0.5 tons is displayed.
REMARK
If 2.2 tons is loaded when the target load is 2.0 tons, and the
amount remaining in the bucket is displayed as 2.8 tons (5.0 -
2.2), the target load has been exceeded, so the alarm buzzer
sounds.
At the same time, “TARGET OVER“ is displayed on the charac-
ter display.
Push the load meter cancel switch to stop the alarm buzzer.
Note that the alarm buzzer does not stop when the starting
switch is turned to the OFF position.
8. Load the target of 0.5 tons from the 3.5 tons loaded in the bucket.
9. After loading, lower the lift arm and then raise it again in order to weigh the amount remaining in the bucket.
The amount remaining in the bucket is weighed and displayed.
10. The amount remaining in the bucket is 3.1 tons.
The target load is 0.5 - (3.5 - 3.1) = 0.1 tons
11. To start the next loading operation, press the load meter
subtotal switch to complete the 1st loading operation.
12. At this point, the amount remaining in the bucket (3.1 tons)
is subtracted from the target load for the next loading oper-
ation, and the result (8.9 tons) is displayed as the target
load.
The amount remaining in the bucket is 3.1 tons.

12.0 - 3.1 = 8.9 tons, so 8.9 tons is displayed as the next
target load.
6-45
13. If the second loading operation is to be carried out without

using the load remaining in the bucket, press the load
meter cancel switch. The target load will return to the initial
setting (12 tons).
The target load is displayed as 12.0 tons.
REMARK
It may not be possible to measure the weight of the load when carrying out the following operations.
When the boom is not kept raised continuously for at least 1.5 sec.
When the boom is operated to RAISE continuously but the lifting speed is not constant
When the boom angle when starting the RAISE operation is near horizontal
If the result of the measurement is not displayed on the load meter, start the scooping operation with the bucket at
a low position (close to the ground surface), raise the boom at a constant speed, and keep the boom raised contin-
uously for at least 1.5 sec.
METHOD OF SETTING TIME ON CLOCK
(The time display is only available on machines equipped with the load meter)

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

then press the (>) or (<) of monitor panel mode selector
switch 2 to select “DAY & TIME ADJUST“.
6-46
4. Press the ( ) of monitor panel mode selector switch 1.

The top line displays “ADJUST 23: 59“.
The bottom line displays “2000/01/01“.
REMARK
Once the time is input, the clock will show the correct time from
that time on.
5. Input the day and time.
The cursor is displayed at each input item in the following order: Year, Month, Day, Hour, Minute.
Use the (>) or (<) of monitor panel mode selector switch 2 to move the numbers up or down and input num-
bers between 0 and 9 at the cursor position.
6. After inputting the number, press the ( ) of monitor panel mode selector switch 1 to select and move the cur-
sor to the next input position.
Repeat Steps 5 and 6 to input and select the numbers from the year to the minute.
7. When the ( ) of monitor panel mode selector switch 1 is

pressed to select the last digit of the minutes, the character
display will return to the normal service meter and time dis-
play.
8. To stop the input operation midway, or if the input is mis-

taken, press the () of monitor panel mode selector switch
1 to go back to the previous display.
6-47
PRINTER OUTPUT
PRINTOUT MODE
(This functions only when the optional printer is installed.)
Three types of output mode (A, B, C) can be selected for the load meter printout.
For details, see “METHOD OF SELECTING PRINTOUT MODE (6-49)“.
A mode: Printout of totals

The number of loads and total amount loaded for each type of material are printed out.
B mode: Printout of subtotals
The total for each load, number of loads, and total amount loaded for each type of material are printed out.
C mode: Printout of operating record

In addition to the items printed out in A mode, the maintenance items and time remaining until maintenance are
also printed out.
REMARK
When a printout is made using C mode, the total number of loads and the total amount loaded is reset.
The printouts shown below are examples of the load meter printouts for the WA470.
6-48
METHOD OF SELECTING PRINTOUT MODE
(This functions only when the optional printer is installed.)

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

then press the (>) or (<) of monitor panel mode selector
switch 2 to select “PRINT TYPE“.
The bottom line will change to display the printout mode “A

< > B < > C“.

2 to set to the desired printout mode.
Three types of output mode (A, B, C) can be selected for

the load meter printout.
For details, see “PRINTOUT MODE (6-48)“.
6. After setting the printout mode, press the () of monitor panel mode selector switch 1.
If the monitor accepts it, the buzzer will give short sounds and the screen will return to the load meter display.
6-49
7. To print out in A or B mode, keep the load meter sub total

switch pressed for at least 2 seconds and the data will be
printed out.
When printing out in C mode, the data will be printed out

immediately when C mode is selected in Step 5.
When the C mode printout is finished, the printout mode

setting will return to A or B.
8. To stop the input operation midway, or if the input is mistaken, press the () of monitor panel mode selector
switch 1 to go back to the previous display.
6-50
OTHER FUNCTIONS OF MACHINE MONITOR 6

The machine monitor also has the following functions.
Odometer, filter/oil replacement time reset, telephone number input, language selection, HST selector function,
monitor lighting adjustment
METHOD OF DISPLAYING ODOMETER
Use this when checking the total distance that the machine has traveled.
1. Check that the character display is showing the service meter or the action code. If it is giving any other dis-
play, turn the starting switch OFF, then turn the starting switch to the ON position and wait for the above dis-
play to be given.

3. Press the (>) and (<) switches of monitor panel mode

selector switch 2 and display “ODO“ (odometer).

mode selector switch 1 or turn the starting switch OFF.
6-51
RESET METHOD FOR FILTER, OIL REPLACEMENT TIME
The filter and oil replacement time is displayed on the character display, so if the filter and oil have been replaced,
reset the filter and oil change time.


and display “MAINTENANCE MONITOR“.

will change to the display in the diagram on the right.
The bottom line shows two items: the replacement time on
the left and the total number of times the item has been
replaced on the right.

2 to display the item (filter or oil) which has reached the
replacement time.

will change to the display in the diagram on the right.
The top line shows [Reset] and [Item to be reset] in turn.
6. When resetting the replacement time, press (>) or (<) of

monitor panel mode selector switch 2, align the cursor with
“YES“, then press () of machine monitor mode selector
switch 1. It will reset and return to the previous screen.
To abort, align the cursor with “NO“, then press () of mon-
7. When resetting the replacement time for another item, carry out the procedure from Step 4. After completing,
press () of monitor panel mode selector switch 1 twice or turn the starting switch OFF.
6-52
INPUT METHOD FOR TELEPHONE NUMBER
It is possible to display the telephone number on the right side of “CALL“ displayed on the character display when
action code “E03“ is generated.


and display “TEL“.
3. Press ( ) of monitor panel mode selector switch 1. It will

change to the display in the diagram on the right.
Once the telephone number is input, the input number will

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

Input from the first digits.
The cursor is displayed at the input position. Press (>) or

(<) of monitor panel mode selector switch 2 and display “0 -
9“. To leave a blank, select “*“.
When the input value is decided, press ( ) of monitor

panel mode selector switch 1. The cursor will move to the
next position.
5. Repeat the procedure in Step 4 until the last digit. At the last digit, press ( ) of monitor panel mode selector
switch 1 to return to the previous screen.
If there is a mistake in the input or the input is to be stopped, press () of monitor panel mode selector switch
1 to return to the previous screen.
switch OFF.
6-53
METHOD FOR SELECTING LANGUAGE
Use this when switching the language displayed on the character display.
The following explanation is for when English is set as the language for the character display.


and display “LGUAGE“.
3. Press the ( ) of machine mode panel selector switch 1.

The presently selected language is displayed.

and select the language.
The available languages are English, Japanese, German, French, Italian, Spanish, and Swedish.
5. After selecting the language, press the ( ) of monitor

panel mode selector switch 1.
To confirm, set the cursor at “YES“, then press the () of

monitor panel mode selector switch 1. The language will
be selected and the screen will return to the previous
screen.
To abort, set the cursor at “NO“, then press the () of mon-

mode selector switch 1 twice or turn the starting switch
OFF.
6-54
METHOD OF SELECTING HST CHANGING FUNCTION
When the speed range selector switch is in 3rd or 4th position, there are two selections available for the HST. Use
this when changing the selection.
Speed range selector switch position

Function
3rd position 4th position
A (default setting) F3, R3 F4, R4
B F3, R2 F4, R2


and display “SELECT HST“.
3. Press the ( ) of monitor mode selector switch 1. The

present HST selection is displayed.
4. Press the (<) or (>) of monitor mode selector switch 2, and

align the cursor with A or B.
5. Press the () of monitor mode selector switch 1.
The HST selection is confirmed and the screen returns to

the previous screen.
switch OFF.
6-55
METHOD OF ADJUSTING MONITOR BRIGHTNESS
Do as follows to adjust the brightness of the monitor.


and display “BRIGHTNESS ADJUST“.

“MONITOR PANEL“ will be displayed on the bottom line
and it will be possible to adjust the brightness of the moni-
tor.
The brightness can be adjusted for the overall monitor or for

the liquid crystal display only.
To adjust only the brightness of the liquid crystal display, press

the (>) or (<) of monitor panel mode selector switch 2 to
switch the display to “LCD PANEL“.
6-56

The screen will change to the display shown on the right
and it will be possible to adjust the brightness.

2 to select a level between L and H (available range: 7
stages).
6. After selecting the brightness, press the () of monitor

panel mode selector switch 1.
The brightness will be selected and the screen will return

to the previous screen.
switch OFF.
6-57
HANDLING MULTI-FUNCTION LEVER ATTACHMENTS, OPTIONS
HANDLING MULTI-FUNCTION LEVER 6
(1) Work equipment lever (3) Directional selector switch actuation switch
(2) Directional selector switch (4) Directional selector pilot lamp
WORK EQUIPMENT LEVER 6
Use this lever (1) to operate the lift arm and bucket.
NOTICE
Position (a): RAISE
When the work equipment control lever is pulled further from

the RAISE position, the lever is stopped in this position until the
lift arm reaches the preset position of the kickout, and the lever Raise
is returned to the HOLD position.
Position (b): HOLD

The lift arm and bucket stop and remain in the same position.
Lower
Position (c): LOWER
AE41484B-A
Position (d): FLOAT
6-58
ATTACHMENTS, OPTIONS HANDLING MULTI-FUNCTION LEVER
Position (e): TILT

When the work equipment control lever is pulled further from Tilt
the TILT position, the lever is stopped in this position until the
bucket reaches the preset position of the positioner, and the
Dump
lever is returned to the HOLD position.
Position (f): DUMP
AE41485B-A
DIRECTIONAL SELECTOR SWITCH 6
This switch (2) is used to switch the direction of travel of the

F Position: FORWARD
N Position: Neutral
R Position: REVERSE
Before operating this switch, check that the condition is as fol-

lows.
q Directional lever is at N
q Directional selector switch actuation switch is at ON
If the condition is not as above, the switch will not work.
For details, see “USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE (6-61)“.
REMARK
When directional selector switch operation switch (3) is ON, if directional lever (2) is not at the N position and
directional selector switch (4) is also not at the N position, the engine will not start.
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH 6
When this switch (3) is turned on, the directional selector

switch is actuated.
Position (a): ON
The directional selector switch is actuated.
Position (b): OFF
The directional selector switch is turned off.
REMARK
Turn this switch ON when the directional lever and directional
selector switch are at the neutral position. At any other posi-
tion, this switch does not work.
Even if the directional selector switch is functioning, when the
directional lever is operated, the operation of the directional
lever is given priority.
6-59
DIRECTIONAL SELECTOR PILOT LAMP 6
This lamp (4) displays the position of the directional selector

switch under the following conditions.
q Directional selector switch operation switch: ON position
q Directional lever: N position
REMARK
Directional lever: Neutral position
Directional selector actuation switch (3): ON position
Directional selector switch (2): Forward or Reverse position
When the starting switch is turned to the ON position with the levers and switches in the following condition, all
directional lever positional pilot lamps (4) will go out.
If directional selector switch (2) is then set to the N position, directional lever positional pilot lamps (4) display the
normal condition “N“.
6-60
ATTACHMENTS, OPTIONS HANDLING MULTI-FUNCTION LEVER
OPERATION 6
USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE 6
WARNING
q When changing direction between FORWARD and
REVERSE, check that the new direction of travel is
safe. There is a blind spot behind the machine, so be
particularly careful when changing direction to travel
in reverse.
q Do not switch between FORWARD and REVERSE
when traveling at high speed.
When switching between FORWARD and REVERSE,
depress the brake to reduce the travel speed suffi-
ciently, then change the direction of travel. (Max.speed
for changing direction: 13 km/h (8.1 MPH))
q When the directional selector switch actuation switch

(3) is at the ON position, if the directional lever (1) is
operated to FORWARD or REVERSE, the machine will
travel in forward or reverse according to the operation
of the directional lever, regardless of the position of
the directional selector switch (2).
Priority is given to the operation of the directional
lever, so be careful when operating.
1. Place the directional lever (1) at the N position.
2. Place the directional selector switch (2) at the N position.
6-61
3. Place the directional selector switch actuation switch (3) at

the ON position (a).
4. Place the directional selector switch (2) at the F (forward)

or R (reverse) position.
REMARK
When the directional selector switch actuation switch (3) is at the ON position, if the directional lever (1) is oper-
ated to FORWARD or REVERSE, the machine will travel in forward or reverse according to the operation of the
directional lever, regardless of the position of the directional selector switch (2).
Priority is given to the operation of the directional lever.
When using directional selector switch (2) again, set directional lever (1) and directional selector switch (2) to the
N position.
6-62
ATTACHMENTS, OPTIONS CENTRAL LUBRICATION SYSTEM
CENTRAL LUBRICATION SYSTEM
OPERATING THE CENTRAL LUBRICATION SYSTEM

The pump with the grease container is located at the left of the
engine bonnet, above the fender.
1. Turn the ignition switch to ON.
This switches on the grease pump.
2. Watch the grease container through the rear window.

If the mixer blades are turning inside the grease container,
the lubrication system is OK.
If the mixer blades are not turning, no automatic lubrication

is taking place.
To eliminate the malfunction, contact your Komatsu dealer.
DISPLAY AND CONTROL UNIT

The display and control unit is protected by a transparent
plastic cover against splashing water and mechanical damage.
For programming, the cover has to be dismounted and,
following programming, reattached with a screwdriver.
6-63
CENTRAL LUBRICATION SYSTEM ATTACHMENTS, OPTIONS
LED-DISPLAY
1. Seven-segment display: Values and operating state
2. Pause time (PAUSE h/lmp)

1
3. Pump operation (CONTACT min/lmp)
4. Monitoring of system function by means of an external 2 PAUSE

h/lmp
cycle switch (CS)
3 CONTACT
min/lmp
5. Monitoring of system function by means of an external
pressure switch (PS) 4
CS
6. Fault message (FAULT)
5
PS
6 FAULT
PUSHBUTTONS
1. Turn on display
Display values and parameters
Set values and parameters
2. Change between programming and display mode
Confirm values (SET)
3. Activatev intermediate lubrication
Clear fault message (DK)
6-64
ATTACHMENTS, OPTIONS CENTRAL LUBRICATION SYSTEM
CHANGING THE LUBRICATION INTERVAL TIMES

The settings when shipping from factory are as follows:
Greasing interval: after 1 hour
Greasing time: 10 minutes.
Step Key Display

1 000 in display flashes
Press for more than 2s
2 Automatically indicates first parameter

Example: ªPause in timer operation
Press briefly LED ªPause flashes
(confirm code)
3 Pause time 1 h
Press briefly
4 Set new value

Example: 6.8 h = 6 h 48 min
5 Indicates next parameter

ªPump running time in timer mode
Press briefly LED ªContact flashes
(confirm new value)
6 Pump running time 4 min
Press briefly
7 Set new value

Example: 3 min
8 Press briefly Confirm new value
9 Press for Changes are written to the memory, and the LED indicators
more than 2s extinguish.
6-65
CENTRAL LUBRICATION SYSTEM ATTACHMENTS, OPTIONS
6-66
INDEX
17
INDEX
7-2
INDEX
INDEX 7
17
A FUSE ......................................................................... 3-46

ADJUSTING WORK EQUIPMENT POSTURE .. 3-94 G
AFTER STARTING ENGINE
GENERAL PRECAUTIONS .................................... 2-7
CHECKS ............................................................ 3-74
GENERAL VIEW ....................................................... 3-2
OPERATIONS .................................................. 3-74
CONTROLS AND GAUGES ............................ 3-3
AIR CONDITIONER ................................................ 3-49
MACHINE ............................................................ 3-2
AXLE SERIAL NO. PLATE ...................................... 1-8
GREASE PUMP ...................................................... 3-45
C GUIDE TO MAINTENANCE .................................... 4-2
CAB DOOR INNER LOCK ..................................... 3-45 H
CAB DOOR OPEN LOCK ...................................... 3-46
HANDLING CAB WIPER ....................................... 3-53
CAB WINDOW OPEN LOCK CANCEL KNOB .. 3-46
HANDLING MULTI-FUNCTION LEVER ............. 6-58
CE-CONFORMING EQUIPMENT ........................ 1-18
EXPLANATION OF COMPONENTS ............ 6-58
MANUFACTURER-SUPPLIED
OPERATION ..................................................... 6-61
CE-CONFORMING ........................................ 1-19
CENTRAL LUBRICATION SYSTEM ................... 6-63 I
CHECK INTRODUCTION ....................................................... 1-6
AFTER STOPPING ENGINE ......................... 3-97
BEFORE STARTING ENGINE, L
ADJUST ............................................................. 3-54 LIFTING MACHINE ............................................... 3-104
CHECKS LOADING
AFTER COMPLETION WORK WITH TRAILERS .............................. 3-101
OF OPERATION .............................................. 3-97 LOCKING ................................................................. 3-98
COLD WEATHER OPERATION ......................... 3-107 LONG-TERM STORAGE ..................................... 3-110
AFTER COLD WEATHER ............................ 3-109 AFTER STORAGE ........................................ 3-110
PRECAUTIONS AFTER BEFORE STORAGE ..................................... 3-110
COMPLETION OF WORK ............................ 3-108 DURING STORAGE ...................................... 3-110
PRECAUTIONS FOR LUBRICANTS
LOW TEMPERATURE .................................. 3-107 SELECTION ...................................................... 4-10
WARMING-UP OPERATION FOR USE ...................................................................... 4-9
STEERING HYDRAULIC CIRCUIT ............ 3-109
CONTROL LEVERS, PEDALS ............................. 3-39 M
COOLANT MACHINE MONITOR ............................................... 3-5
HANDLING .......................................................... 4-4 MACHINE MONITOR WITH LOAD METER ........ 6-3
SELECTION ...................................................... 4-10 EXPLANATION OF COMPONENTS .............. 6-3
USE ...................................................................... 4-9 MACHINE MONITOR ........................................ 6-6
MACHINE SERIAL NO. PLATE AND POSITION 1-7
D MAINTENANCE SCHEDULE CHART ................. 4-17
DIRECTIONS OF MACHINE ................................... 1-6 MOVING MACHINE
DMENSIONS ........................................................... 1-17 DIRECTIONAL, SPEED .................................. 3-77
E MOVING THE MACHINE
STOPPING MACHINE .................................... 3-77
ELECTRIC SYSTEM
OUTLINE ............................................................. 4-7 N
EMERGENCY LOWERING SYSTEM ................. 2-22 NECESSARY INFORMATION ................................ 1-7
ENGINE SERIAL NO. PLATE AND POSITION ... 1-7 NOISE EMISSION LEVELS .................................... 5-4
EQUIPMENT, CE-CONFORMING ....................... 1-18
EU DIRECTIVES ....................................................... 1-3 O
OIL
F HANDLING .......................................................... 4-4
FIRE EXTINGUISHER ............................................. 2-7 OPERATING DATA ................................................ 1-17
FIRST AID KIT ........................................................... 2-7 OPERATION ............................................................ 3-54
FOREWORD .............................................................. 1-2
FUEL P
HANDLING .......................................................... 4-4 PARKING MACHINE .............................................. 3-96
SELECTION ...................................................... 4-10 PERFORMING OIL CLINIC
USE ...................................................................... 4-9 HANDLING .......................................................... 4-4
7-3
INDEX
POSITION OF SERVICE MATER .......................... 1-9 TRANSPORTATION PROCEDURE .................. 3-101

POWER OUTLET ................................................... 3-48 TROUBLESHOOTING ......................................... 3-111
PRECAUTIONS FOR MAINTENANCE ............... 2-29 IF BATTERY IS DISCHARGED .................. 3-113
PRECAUTIONS FOR OPERATION .......... 2-17, 3-92 OTHER TROUBLE ........................................ 3-117
BATTERY .......................................................... 2-26 TOWING THE MACHINE ............................. 3-111
OPERATION ..................................................... 2-19 WHEN MACHINE RUNS OUT OF FUEL .. 3-111
STARTING ENGINE ........................................ 2-17 TURNING ................................................................. 3-82
TOWING ............................................................ 2-28
TRANSPORTATION ....................................... 2-25
U
PRECAUTIONS WITH TIRES .............................. 2-36 UNLOADING
WORK WITH TRAILERS .............................. 3-101
R
ROPS/FOPS-CAB SERIAL NO. PLATE ............... 1-8
V
VIBRATION LEVEL .................................................. 5-4
S
SAFETY BAR ........................................................... 3-44
W
SAFETY CRITICAL PARTS WEAR PARTS ........................................................... 4-8
PERIODIC REPLACEMENT .......................... 4-16 LIST ...................................................................... 4-8
SAFETY INFORMATION] ........................................ 1-4 WEIGHTS ................................................................. 1-17
SAFETY LABELS ...................................................... 2-3 WHEEL LOADER
LOCATION OF SAFETY LABELS .................. 2-3 WORK POSSIBLE USING ............................. 3-86
PRESENTATION ............................................... 2-4 WORK EQUIPMENT
SEAT OPERATOR SERIAL NO. PLATE .............. 1-8 OPERATION ..................................................... 3-84
SELECTING BUCKET AND TIRES ....................... 6-2
SERVICE
OUTLINES .......................................................... 4-4
SERVICE PROCEDURE ....................................... 4-19
CHECK BEFORE STARTING ....................... 4-38
EVERY 100 HOURS SERVICE ..................... 4-40
EVERY 1000 HOURS SERVICE .................. 4-51
EVERY 50 HOURS SERVICE ....................... 4-39
INITIAL 250 HOURS SERVICE ..................... 4-19
WHEN REQUIRED .......................................... 4-20
SLOW BLOW FUSE ............................................... 3-48
STANDARD TIGHTENING TORQUES
FOR BOLTS AND NUTS ....................................... 4-15
STARTING ENGINE ............................................... 3-70
STEERING TILT LOCK LEVER ........................... 3-43
STOPPING ENGINE .............................................. 3-76
STORAGE BOX ...................................................... 3-48
SWITCHES .............................................................. 3-30
T
TABLE TO ENTER SERIAL NO.
AND DISTRIBUTOR ................................................. 1-9
TECHNICAL DATA ................................................... 5-2
NOISE EMISSION LEVELS ............................. 5-4
VIBRATION LEVEL ........................................... 5-4
TIRES
HANDLING ........................................................ 3-99
TIRE PRESSURE ............................................ 3-99
TORQUE LIST ......................................................... 4-15
TOWING PIN ........................................................... 3-45
TRACTION CONTROL .......................................... 3-32
TRANSMISSION SERIAL NO. PLATE .................. 1-8
TRANSPORTATION ............................................. 3-101
7-4
NOTES
18
NOTES NOTES
NOTES 8
8-2
NOTES NOTES
8-3
© 2003 Komatsu Hanomag GmbH
All Rights Reserved
Printed in Europe
10.2003

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VEAM240100

Operation & Maintenance

Storage location for the Operation and Maintenance Manual:

Notes on subsequent installation of electrical and electronic equipment and components

q The unit must be fixed in position

Example of safety message using signal word

Other signal words

This word is used for information that is useful to know.

For details of safety labels, see "SAFETY LABELS (2-3)".

Safety labels using pictogram

Safety pictograms use a picture to express a level of hazard-

The explanations, values, and illustrations in this manual were

The numbers in circles in the illustrations correspond to the

The transport of persons in the work equipment is strictly forbidden!

MACHINE SERIAL NO. PLATE AND POSITION 1

ENGINE SERIAL NO. PLATE AND POSITION 1

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

ROPS/FOPS-CAB SERIAL NO. PLATE

AXLE SERIAL NO. PLATE

TRANSMISSION SERIAL NO. PLATE

SEAT OPERATOR SERIAL NO. PLATE

POSITION OF SERVICE METER 1

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1

Machine serial No.

CENTRAL WARNING LAMP .................................................................................................................... 3-7

PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES .................................................................. 3-92

GREASE ................................................................................................................................................... 4-5

CHECK PLAY OF TURBOCHARGER ROTOR...................................................................................... 4-54

CENTRAL LUBRICATION SYSTEM ............................................................................................................... 6-63

DIMENSIONS, WEIGHTS AND OPERATING DATA

WA320-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA

Measurements, operating data

419-72-H2100 2,7 1.040

419-72-H2160 2,7 1.118

419-72-H2170 2,7 2.217

419-72-H2180 2,85 1.325

419-72-H2130 3,0 1.265

419-72-H2150 3,1 1.472

MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING

The responsibility for observing valid regulations in the case of

LOCATION OF SAFETY LABELS 2

PRESENTATION OF SAFETY LABELS 2

Read the Operator’s Lower working device

3 Precautions when traveling in reverse 4 Use Komatsu oil only

Honk to alert people

5 Do not enter (421-93-H1320) 6 Precautions for safety bar (421-93-H1330)

Keep away from the

Sign indicates a burn Sign indicates a burn

Allow coolant to cool Allow hydraulic oil to

9 Precautions when handling battery cable 10 High pressure warning (421-93-H1300)

Do not disassembly the

11 Do not climb on fender (421-93-H1400) 12 Do not open when engine is running

Do not stand on this Turn off engine before

Keep a safe distance Keep away when the

IF ABNORMALITIES ARE FOUND

CLOTHING AND PERSONAL PROTECTIVE ITEMS

q Always wear a hard hat and safety shoes. If the nature of

q Check that all protective equipment functions properly

FIRE EXTINGUISHER AND FIRST AID KIT