Ten00089-06 Wa380-5 Wheel Loader

TEN00089-06
WHEEL LOADER WA380 -5

SERIAL NUMBERS 60001 and up
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
NOTICE
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
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1-1
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FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions 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. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points.
Read this manual thoroughly and understand its contents fully.
Read the safety messages and safety labels given in this manual carefully so that they should be understood fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved
in working on the machine can consult it periodically.
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
In this manual, measurements are expressed in international standard units (SI). For the reference purpose, weight units used in
the past are also displayed in ( ).
Storage location for the Operation and Maintenance Manual:

Pocket (1) at rear of operator's seat
1-2
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal 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
serious 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
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the work equipment 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
protect 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.
1-3
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SAFETY INFORMATION FOREWORD
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when performing
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram

Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
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 condition at the top
or left side, and the method of avoiding the hazardous 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))
1-4
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FOREWORD INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Digging work
Smoothing
Pushing work
Loading work
For details of the operating procedure, see "WORK POSSIBLE USING WHEEL LOADER (PAGE 3-127)".
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
1-5
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NECESSARY INFORMATION FOREWORD
NECESSARY INFORMATION
When requesting service or ordering replacement parts, contact your Komatsu distributor of the following items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE

On the center right of the front frame.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE

This name plate is affixed on the oil cooler at the side of engine cylinder block on the left side of machine.
EPA: Environmental Protection Agency, U.S.A.
1-6
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FOREWORD NECESSARY INFORMATION
POSITION OF SERVICE METER

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

Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
1-7
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CONTENTS FOREWORD
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 3
INTRODUCTION 1- 5
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 5
NECESSARY INFORMATION 1- 6
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 6
ENGINE SERIAL NO. PLATE 1- 6
POSITION OF SERVICE METER 1- 7
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 7
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 11
PRECAUTIONS FOR OPERATION 2- 20
STARTING ENGINE 2- 20
OPERATION 2- 22
TRANSPORTATION 2- 28
BATTERY 2- 29
TOWING 2- 31
PRECAUTIONS FOR MAINTENANCE 2- 32
PRECAUTIONS WITH TIRES 2- 39
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 6
MACHINE MONITOR 3- 6
SWITCHES 3- 36
CONTROL LEVERS, PEDALS 3- 50
STEERING TILT LOCK LEVER 3- 55
CAP WITH LOCK 3- 56
FRAME LOCK BAR 3- 58
TOWING PIN 3- 58
GREASE PUMP 3- 59
CAB DOOR OPEN LOCK 3- 59
CAB WINDOW OPEN LOCK CANCEL KNOB 3- 59
FUSE 3- 60
SLOW BLOW FUSE 3- 61
POWER OUTLET 3- 62
AM/FM RADIO 3- 63
AM/FM RADIO-CASSETTE STEREO 3- 69
AIR CONDITIONER 3- 77
HANDLING AUTO AIR CONDITIONER 3- 82
HANDLING CAB WIPER 3- 89
OPERATION 3- 90
CHECK BEFORE STARTING ENGINE, ADJUST 3- 90
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FOREWORD CONTENTS
STARTING ENGINE 3-106

OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-110
STOPPING ENGINE 3-112
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE 3-113
TURNING 3-123
OPERATION OF WORK EQUIPMENT 3-125
WORK POSSIBLE USING WHEEL LOADER 3-127
PRECAUTIONS FOR OPERATION 3-133
ADJUSTING WORK EQUIPMENT POSTURE 3-135
PARKING MACHINE 3-137
CHECKS AFTER COMPLETION OF OPERATION 3-139
LOCKING 3-139
HANDLING THE TIRES 3-140
TRANSPORTATION 3-142
TRANSPORTATION PROCEDURE 3-142
LOADING, UNLOADING WORK WITH TRAILERS 3-142
LIFTING MACHINE 3-146
COLD WEATHER OPERATION 3-148
PRECAUTIONS FOR LOW TEMPERATURE 3-148
PRECAUTIONS AFTER COMPLETION OF WORK 3-149
AFTER COLD WEATHER 3-149
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER 3-150
LONG-TERM STORAGE 3-151
BEFORE STORAGE 3-151
DURING STORAGE 3-151
AFTER STORAGE 3-152
TROUBLESHOOTING 3-153
WHEN MACHINE RUNS OUT OF FUEL 3-153
METHOD OF TOWING MACHINE 3-154
IF BATTERY IS DISCHARGED 3-159
OTHER TROUBLE 3-162
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
OUTLINE OF ELECTRIC SYSTEM 4- 7
WEAR PARTS 4- 8
WEAR PARTS LIST 4- 8
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 11
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 12
TORQUE LIST 4- 12
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 13
MAINTENANCE SCHEDULE CHART 4- 14
MAINTENANCE SCHEDULE CHART 4- 14
SERVICE PROCEDURE 4- 16
INITIAL 250 HOURS SERVICE 4- 16
INITIAL 1000 HOURS SERVICE 4- 16
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CONTENTS FOREWORD
WHEN REQUIRED 4- 17
CHECK BEFORE STARTING 4- 41
EVERY 50 HOURS SERVICE 4- 42
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
SELECTING BUCKET AND TIRES 6- 2
HANDLING LOAD METER 6- 3
GENERAL LOCATIONS 6- 3
LOAD METER FUNCTIONS 6- 5
HANDLING LOAD METER DISPLAY 6- 9
METHOD OF SETTING TIME ON CLOCK 6- 30
PRINTER OUTPUT 6- 32
HANDLING TORQUE CONVERTER LOCK-UP 6- 35
GENERAL LOCATIONS 6- 35
METHOD OF OPERATION 6- 36
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED 6- 37
HANDLING AUTO-GREASING SYSTEM 6- 38
METHOD OF OPERATING AUTO-GREASING SYSTEM 6- 38
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM 6- 44
TROUBLESHOOTING 6- 44
HANDLING JOYSTICK STEERING SYSTEM 6- 45
STRUCTURE AND FUNCTION OF JOYSTICK STEERING 6- 47
GETTING IN OR OUT OF OPERATOR'S CAB 6- 49
ADJUSTMENT OF JOYSTICK CONSOLE 6- 49
OPERATION METHOD OF JOYSTICK STEERING SYSTEM 6- 50
HANDLING EPC WORK EQUIPMENT LEVER 6- 53
OPERATIONAL FEATURES 6- 53
SWITCHES 6- 53
SEMI AUTO DIGGING OPERATIONS 6- 54
METHOD OF REMOTE POSITIONER 6- 56
HANDLING MULTI FUNCTION MONO-LEVER 6- 58
USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE 6- 62
INDEX 7- 1
1 - 10
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SAFETY SAFETY
SAFETY
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS
SAFETY RULES 2- 11
IF ABNORMALITIES ARE FOUND 2- 11
CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 11
FIRE EXTINGUISHER AND FIRST AID KIT 2- 11
SAFETY FEATURES 2- 11
KEEP MACHINE CLEAN 2- 12
INSIDE OPERATOR'S COMPARTMENT 2- 12
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 2- 12
HANDRAILS AND STEPS 2- 13
MOUNTING AND DISMOUNTING 2- 14
NO PEOPLE ON ATTACHMENTS 2- 14
DO NOT GET CAUGHT IN ARTICULATED PORTION 2- 14
PREVENTION OF BURNS 2- 14
FIRE PREVENTION 2- 15
ACTION IF FIRE OCCURS 2- 16
WINDOW WASHER LIQUID 2- 16
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 2- 16
PRECAUTIONS FOR ATTACHMENTS, OPTIONS 2- 16
UNAUTHORIZED MODIFICATION 2- 16
SAFETY AT WORKSITE 2- 17
WORKING ON LOOSE GROUND 2- 17
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 18
ENSURE GOOD VISIBILITY 2- 18
VENTILATION FOR ENCLOSED AREAS 2- 18
CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 19
EMERGENCY EXIT FROM OPERATOR'S CAB 2- 19
BE CAREFUL ABOUT ASBESTOS DUST 2- 19
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SAFETY SAFETY
PRECAUTIONS FOR OPERATION 2- 20

STARTING ENGINE 2- 20
CHECKS BEFORE STARTING ENGINE 2- 20
PRECAUTIONS WHEN STARTING 2- 20
PRECAUTIONS IN COLD AREAS 2- 21
OPERATION 2- 22
CHECKS BEFORE OPERATION 2- 22
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 22
PRECAUTIONS WHEN TRAVELING 2- 23
TRAVELING ON SLOPES 2- 24
PROHIBITED OPERATIONS 2- 25
PRECAUTIONS WHEN OPERATING 2- 25
METHODS OF USING BRAKE 2- 26
OPERATE CAREFULLY ON SNOW 2- 26
PARKING MACHINE 2- 27
TRANSPORTATION 2- 28
LOADING AND UNLOADING 2- 28
SHIPPING 2- 28
BATTERY 2- 29
BATTERY HAZARD PREVENTION 2- 29
STARTING WITH BOOSTER CABLES 2- 30
TOWING 2- 31
WHEN TOWING 2- 31
2-3
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SAFETY SAFETY
PRECAUTIONS FOR MAINTENANCE 2- 32

WARNING TAG 2- 32
KEEP WORK PLACE CLEAN AND TIDY 2- 32
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 32
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE 2- 33
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 34
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF 2- 34
PROPER TOOLS 2- 35
ACCUMULATOR 2- 35
PERSONNEL 2- 35
ATTACHMENTS 2- 35
WORK UNDER THE MACHINE 2- 36
NOISE 2- 36
PRECAUTIONS WHEN USING HAMMER 2- 36
REPAIR WELDING 2- 36
REMOVING BATTERY TERMINAL 2- 36
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 37
HANDLING HIGH-PRESSURE HOSES 2- 37
WASTE MATERIALS 2- 37
MAINTENANCE OF AIR CONDITIONER 2- 37
COMPRESSED AIR 2- 38
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2- 38
PRECAUTIONS WITH TIRES 2- 39

HANDLING TIRES 2- 39
PRECAUTIONS WHEN STORING TIRES 2- 39
2-4
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SAFETY SAFETY LABELS
SAFETY LABELS
The following safety labels are used on this machine. Be sure that you fully understand the correct position and
content of these safety labels.
To ensure that the content of these safety labels can be read properly, be sure that they are in the correct place and
always keep them clean. When cleaning them, use soap and water. Do not use organic solvents or gasoline.
These may cause the safety labels to peel off.
If the safety labels are damaged or lost, or cannot be read, replace them with new parts. For details of the part
numbers, see this manual or check on the actual part, and order the new part from your Komatsu distributor.
There are also other labels in addition to the safety labels. Handle these labels in the same way.
LOCATION OF SAFETY LABELS
2-5
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SAFETY LABELS SAFETY
SAFETY LABELS
(1) Caution before starting (09651-03001)
(2) Caution for leaving the operator's seat (09654-03001)
(3) Caution when traveling in reverse
Please request part No. 421-93-23251 for this safety label.
2-6
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(4) Caution for going close to electric cables (09801-13001)
(5) Caution to keep away from movable parts (09162-23000)
(6) Caution for frame lock bar (09161-23000)
2-7
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(7) Caution for parking brake (421-93-23351)
(8) Warning for hot cooling water (09668-03001)
(9) Caution when oil is at high temperature (09653-03001)
(10) Caution for handling battery cable (09808-03000)
2-8
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(11) High pressure warning (09659-53000)
(12) Do not climb on fender (09805-03000)

(Machines with equipped with rear full fender)
(13) "Do not open when engine is running" sign

(09667-03001)
(14) "Do not come near machine" sign (09812-13000)
(15) "Do not go under work equipment" sign (09807-C0883)
2-9
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(16) "Do not modify ROPS" sign (09620-30201)
(17) Prohibited to start by short-circuiting (09842-A0481)
2 - 10
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SAFETY GENERAL PRECAUTIONS
GENERAL PRECAUTIONS
SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions in this manual when operating or performing maintenance on
the machine.
If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate
or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger.
When working with another operator or with the person on the worksite traffic duty, discuss the content of the
operation beforehand and use the determined signals when performing the operation.
IF ABNORMALITIES ARE FOUND

If you find any problems 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 machine monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.
CLOTHING AND PERSONAL PROTECTIVE ITEMS

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

Always follow the precautions below to prepare for action if any injury or fire should occur.
Be sure that fire extinguishers have been provided and read the
labels to ensure that you know how to use them in emergencies.
Perform periodic inspection and maintenance to ensure that the
fire extinguisher can always be used.
Provide a first aid kit in the storage point. Perform periodic
checks and add to the contents if necessary.
SAFETY FEATURES
Be sure that all guards, covers and mirrors are in their proper position. Have guards and covers repaired
immediately if they are damaged.
Understand the method of use of safety features and use them properly.
Never remove any safety features. Always keep them in good operating condition.
2 - 11
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GENERAL PRECAUTIONS SAFETY
KEEP MACHINE CLEAN

If water gets into the electrical system, there is a hazard that it
will cause malfunctions or misoperation. Do not use water or
steam to wash the electrical system (sensors, connectors).
If inspection and maintenance is performed 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

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

Before standing up from the operator's seat to adjust the
operator's seat, always lower the work equipment, set work
equipment lock lever (1) to the LOCK position and parking brake
switch (2) to the ON position, then stop the engine.
If you accidentally touch the travel or swing lever when they are
not locked. The work equipment may suddenly move and cause
serious injury.
When leaving the machine, always lower the work equipment to
the ground, set work equipment lock lever (1) to the LOCK
position and parking brake switch (2) to the ON position, then
stop the engine. Lock all places and always take the key with
you and leave it in the specified location.
2 - 12
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HANDRAILS AND STEPS

To prevent personal injury or death caused by slipping or falling off the machine, always observe the following.
Use the handrails and steps marked by arrows in the figure on
the right when getting on or off the machine.
To ensure safety, always face the machine and maintain

three-point contact (both feet and one hand, or both hands and
one foot) with the handrails and steps to ensure that you support
yourself.
When entering the cab, open the cab door, push the door
securely into catcher (1) to hold in position, then use the handrail
on the inside to get on the machine.
For details of the method of releasing the door lock, see "CAB
DOOR OPEN LOCK (PAGE 3-59)".
Do not grip the control levers and work equipment lock lever
when getting on or off the machine.
Never climb on the engine hood or covers where there are no
non-slip pads.
Never move from the step at the rear of the machine or the step
at the side of the cab to stand on top of the tire.
Before getting on or off the machine, check the handrails and steps, and if there is any oil, grease, or mud on
them, wipe it off immediately. In addition, repair any damage and tighten any loose bolts.
Do not get on or off the machine while holding tools in your hand.
2 - 13
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MOUNTING AND DISMOUNTING

Never jump on or off the machine. Never get on or off a moving machine.
If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try
to stop it.
NO PEOPLE ON ATTACHMENTS
Never let anyone ride on the work equipment, or other attachments. There is a hazard of falling and suffering serious
injury or death.
DO NOT GET CAUGHT IN ARTICULATED PORTION

If the clearance at the articulating portion changes, it will lead to
serious personal injury.
Do not allow anyone to come inside the articulation range.
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
To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to a
temperature where it is possible to touch the radiator cap by
hand before starting the operation. Even when the coolant has
cooled down, loosen the cap slowly to relieve the pressure
inside the radiator before removing the cap.
Hot oil
To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to a temperature where it
is possible to touch the cap or plug by hand before starting the
operation. Even when the oil has cooled down, loosen the cap
or plug slowly to relieve the internal pressure before removing
the cap or plug.
2 - 14
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FIRE PREVENTION
Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particularly
flammable and can be hazardous. To prevent fire, always
observe the following:
Do not smoke or use any open flame near fuel or oil.
Stop the engine before refueling.
Do not leave the machine while adding fuel or oil.
Tighten all fuel and oil caps securely.
Do not spill fuel on overheated surfaces or on parts of the
electrical system.
Use well-ventilated areas for adding or storing oil and fuel.
Keep oil and fuel in the determined place and do not allow
unauthorized persons to enter.
After adding fuel or oil, wipe up any spilled fuel or oil.
When performing grinding or welding work on the chassis,
move any flammable materials to a safe place before
starting.
When washing parts with oil, use a non-flammable oil. Diesel
oil and gasoline may catch fire, so do not use them.
Put greasy rags and other flammable materials into a safe
container to maintain safety at the work place.
Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
Fire caused by accumulation of flammable material.

Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed
around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.
Fire coming from electric wiring

Short circuits in the electrical system can cause fire.
Always keep electric wiring connections clean and securely tightened.
Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair
or replace any damaged wiring.
Fire coming from hydraulic line

Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the
hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.
Explosion caused by lighting equipment

When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with
anti-explosion specifications. If such lighting equipment is not used, there is danger of explosion that may
cause serious injury or death.
When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual.
2 - 15
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ACTION IF FIRE OCCURS

If a fire occurs, escape from the machine as follows.
Turn the starting switch OFF to stop the engine.
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.
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)

Install ROPS when working in places where there is danger of
falling rocks, such as in mines and quarries, or in places where
there is danger of rolling over.
If ROPS is installed, do not remove it when operating the
machine.
ROPS is installed to protect the operator when machine rolls
over. When machine rolls over, ROPS supports its weight and
absorbs its impact energy.
If ROPS is modified, its strength may be reduced. When
modifying, consult your Komatsu distributor.
If ROPS is damaged or deformed by falling objects or by rolling
over, its strength will be reduced and it will not be able to fulfill
its function properly. In such cases, always Komatsu contact
your distributor for advice of the method of repair.
Even if ROPS is installed, always fasten your seat belt properly
when operating the machine. If you do not use your fasten your
seat belt properly, it cannot display its effect.
PRECAUTIONS FOR ATTACHMENTS, OPTIONS

When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore
consult your Komatsu distributor for advice.
Any injuries or death, accidents, product failures or other property damages resulting from the use of
unauthorized attachments or parts will not be the responsibility of Komatsu.
When installing and using optional attachments, read the instruction manual for the attachment, and the general
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.
Komatsu will not be responsible for any injuries or death, accidents, product failures or other property damages
resulting from modifications made without authorization from Komatsu.
2 - 16
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SAFETY AT WORKSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
When performing operations near combustible materials such as attatched roofs, dry leaves or dry grass, there
is a hazard of fire, so be careful when operating.
Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do
not operate where there is a hazard of landslides or falling rocks.
If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify their
locations. Be careful not to sever or damage any of these lines.
Take action to prevent unauthorized people from approaching
the jobsite.
When working on public roads, position flagmen and erect
barriers to ensure the safety of passing traffic and pedestrians.
When traveling or operating in shallow water or on soft ground,
check the shape and condition of the bedrock, and the depth
and speed of flow of the water before starting operations.
Always design and maintain the roads on the jobsite so that the
machines can travel safely.
WORKING ON LOOSE GROUND

Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after
earthquakes is weak in these areas.
When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the
machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe
and to prevent the machine from rolling over or falling.
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DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not travel or operate the machine near electric cables. There is
a hazard of electric shock, which may cause serious personal
injury or death. On jobsites where the machine may go close to
electric cables, always observe the followings.
Before starting work near electric cables, inform the local power
company of the work to be performed, and ask them to take the
necessary action.
Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death. Always
Voltage of Cables Safety Distance
maintain a safe distance (see the table on the right) between the 100 V, 200 V Over 2 m (7 ft)
machine and the electric cable. Check with the local power 6,600 V Over 2 m (7 ft)
company about safe operating procedure before starting 22,000 V Over 3 m (10 ft)
operations. 66,000 V Over 4 m (14 ft)
To prepare for any possible emergencies, wear rubber shoes 154,000 V Over 5 m (17 ft)
and gloves. Lay a rubber sheet on top of the seat, and be careful
187,000 V Over 6 m (20 ft)
not to touch the chassis with any exposed part of your body.
275,000 V Over 7 m (23 ft)
Use a signalman to give warning if the machine approaches too
close to the electric cables. 500,000 V Over 11 m (36 ft)
When performing operations near high voltage cables, do not let
anyone near the machine.
If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should
not leave the operator's compartment until it has been confirmed that the electricity has been shut off.
Also, do not let anyone near 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.
Position a signalman if there are areas at the rear of the machine where the visibility is not good.
When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up
additional lighting in the work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
VENTILATION FOR ENCLOSED AREAS

Exhaust fumes from the engine can kill.
If it is necessary to start the engine within an enclosed area, or
when handling fuel, flushing oil, or paint, open the doors and
windows to ensure that adequate ventilation is provided to
prevent gas poisoning.
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CHECKING SIGNALMAN'S SIGNALS AND SIGNS

Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
Only 1 signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.
EMERGENCY EXIT FROM OPERATOR'S CAB

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

Asbestos dust in the air can cause lung cancer if it is inhaled. There
is danger of inhaling asbestos when working on jobsites handling
demolition work or work handling industrial waste. Always observe
the following.
Spray water to keep down the dust when cleaning. Do not use
compressed air for cleaning.
If there is danger that there may be asbestos dust in the air,
always operate the machine from an upwind position. All
workers should use an approved respirator.
Do not allow other persons to approach during the operation.
Always observe the rules and regulations for the work site and
environmental standards.
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use
genuine Komatsu parts.
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PRECAUTIONS FOR OPERATION SAFETY
PRECAUTIONS FOR OPERATION

STARTING ENGINE
If there is a warning tag hanging from the work equipment control
lever, do not start the engine or touch the levers.
CHECKS BEFORE STARTING ENGINE

Perform the following checks before starting the engine at the beginning of the day's work.
Remove all dirt from the surface of the window glass to ensure a good view.
Remove all dirt from the surface of the lens of the front lamps, working lamps, and rear combination lamp, and
check that they light up correctly.
Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and check
for damage to the electric wiring.
Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake pedal,
and check that the pedals work properly.
Adjust the operator's seat to a position where it is easy to perform operations, and check that there is no damage
or wear to the seat belt or mounting clamps.
Check the operation of the instruments and gauges, check the angle of the mirror, and check that the control
levers are all at the Neutral position.
Before starting the engine, make sure that the work equipment lock lever is in the LOCK position.
Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. See "ADJUST
REAR VIEW MIRROR (PAGE 3-103)".
Check that there are no persons or obstacles above, below, or in the area around the machine.
PRECAUTIONS WHEN STARTING

Start and operate the machine only while seated.
Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a personal
injury or death or fire.
When starting the engine, sound the horn as a warning.
Do not allow anyone apart from the operator to ride on the machine.
When starting the engine, always check that the work equipment control levers are at the HOLD position.
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SAFETY PRECAUTIONS FOR OPERATION
PRECAUTIONS IN COLD AREAS

Perform the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery 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 - 21
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OPERATION
CHECKS BEFORE OPERATION

When performing the checks, move the machine to a wide area where there are no obstructions, and operate slowly.
Do not allow anyone near the machine.
Always fasten your seat belt.
Check the operation of travel, steering and brake systems, and
work equipment control system.
Check for any problem in the sound of the machine, vibration,
heat, smell, or gauges; check also that there is no leakage of oil
or fuel.
If any problem is found, perform repairs immediately.
Before driving the machine or starting operations, check that

frame lock bar (1) is securely fixed at FREE position.
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles.
Before travelling, sound the horn to warn people in the area.
Always operate the machine only when seated.
Do not allow anyone apart from the operator to ride on the machine.
Check that the backup alarm (alarm buzzer when machine travels in reverse) works properly.
Always lock the door and windows of the operator's compartment in position (open or closed).
On jobsites where there is a hazard of flying objects or of objects entering the operator's compartment, check that
the door and windows are securely closed.
If there is an area to the rear of the machine which cannot be
seen, position a signal person. Take special care not to hit other
machines or people when turning or swinging the machine.
Always be sure to perform the above precautions even when the
machine is equipped with mirrors.
2 - 22
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PRECAUTIONS WHEN TRAVELING

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.
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.
When traveling on rough ground, travel at low speed and do not operate the steering suddenly. There is danger
that the machine may turn over. The work equipment may hit the ground surface and cause the machine to lose
its balance, or may damage the machine or structures in the area.
Avoid traveling over obstacles when possible. If the machine has to travel over an obstacle, keep the work
equipment close to the ground and travel at low speed. Never travel over obstacles which make the machine tilt
strongly to one side.
When traveling or performing operations, always keep a safe distance from people, structures, or other machines
to avoid coming into contact with them.
When passing over bridges or structures, check first that the structure is strong enough to support the weight of
the machine. When traveling on public roads, check first with the relevant authorities and follow their instructions.
When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, operate
slowly and be extremely careful not to let the machine or work equipment hit anything.
Always obey the traffic regulations when traveling on public roads. This machine travels at a lower speed than
normal automobiles, so keep to the side of the road and be careful to leave the center of the road free for other
vehicles.
If you drive the machine at high speed continuously for a long time, the tires will overheat and the internal pressure
will become abnormally high. This may cause the tires to burst. If a tire bursts, it produces an extremely large
destructive force, and this may cause serious injury or accident.
If you are going to travel continuously, please consult your Komatsu distributor.
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TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side, always observe the following.
When traveling on slopes, keep the work equipment height "A"
at 20 to 30 cm (8 to 12 in) above the ground. In case of
emergency, quickly lower the work equipment to the ground to
help the machine to stop.
Always travel straight up or down a slope. Traveling at an angle

or across the slope is extremely dangerous.
Do not turn on slopes or travel across slopes. Always go down
to a flat place to change the position of the machine, then travel
on to the slope again.
Travel on grass, fallen leaves, or wet steel plates with low speed. Even with slight slopes there is a hazard that
the machine may slip.
If the engine stops, depress the brake pedal immediately, lower the bucket to the ground, and apply the parking
brake to stop the machine.
When traveling downhill, never shift gear or place the 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.
When traveling downhill, travel slowly. If necessary, use the braking force of the engine together with the brake
pedal to control the travel speed.
When traveling up or down hills with a loaded bucket, always travel with the bucket facing uphill. If the machine
travels with the bucket facing downhill, there is danger that the machine may tip over.
2 - 24
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PROHIBITED OPERATIONS
It is dangerous to excavate the bottom of a rock face. Never do
this.
It is dangerous to use the bucket or lift arm for crane operations,

so do not carry out such operations.
Do not pass the bucket over the head of other workers or over
the operator's seat of dump trucks or other hauling equipment.
The load may spill or the bucket may hit the dump truck and
cause serious personal injury or death.
PRECAUTIONS WHEN OPERATING

When using the machine, to prevent personal injury caused by damage to the work equipment or by the machine
overturning due to overloading, do not exceed the permitted performance of the machine or the maximum
permitted load for the structure of the machine.
If the engine cannot be started again after it has stopped, immediately operate the work equipment control levers
to lower the work equipment to the ground. (After the engine stops, the accumulator allows the work equipment
to be operated for a limited time.)
Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or when
dropping soil over a cliff, dump 1 pile, then use the next pile of soil to push the first pile.
The load suddenly becomes lighter when the soil is pushed over a cliff or when the machine reaches the top of
a slope. When this happens, there is danger that the travel speed will suddenly increase, so be sure to reduce
the speed.
When the bucket is fully loaded, never start, turn, or stop the
machine suddenly. There is danger of the machine turning over.
2 - 25
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When handling unstable loads, such as round or cylindrical

objects, or piled sheets, if the work equipment is raised high,
there is danger that the load may fall on top of the operator'
compartment and cause serious injury or damage.
When handling unstable loads, be careful not to raise the work
equipment too high or tip the bucket back too much.
If the work equipment is suddenly lowered or suddenly stopped,
the reaction may cause the machine to tip over. Particularly
when carrying a load, be sure to operate the work equipment
carefully.
When operating in tunnels, under bridges, under electric wires,
or other places where the height is limited, be extremely careful
not to let the machine body or work equipment hit anything.
To prevent accidents caused by hitting other objects, always
operate the machine at a speed which is safe for operation,
particular in confined spaces, indoors, and in places where there
are other machines.
METHODS OF USING BRAKE

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

Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine,
and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly
careful when working on slopes.
With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over or make it impossible for the machine to escape.
If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful
not to leave the road shoulder or to get trapped in a snow drift.
When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be
seen. There is a hazard of the machine tipping over or hitting covered objects, so always perform operations
carefully.
When traveling on snow-covered roads, always fit tire chains.
When traveling on snow-covered slopes, never apply the foot brake suddenly. Reduce the speed and use the
engine as a brake while applying the foot brake intermittently (depress the brake intermittently several times). If
necessary, lower the bucket to the ground to stop the machine.
2 - 26
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PARKING MACHINE
Park the machine on firm, level ground.
Select a place where there is no hazard of landslides, falling
rocks, or flooding.
Lower the work equipment completely to the ground.
When leaving the machine, set work equipment lock lever (1) to
the LOCK position and parking brake switch (2) to the ON
position, and stop the engine.
Always close the operator's cab door, and use the key to lock all
the equipment in order to prevent any unauthorized person from
moving the machine. Always remove the key, take it with you,
and leave it in the specified place.
If it is necessary to park the machine on a slope, set blocks

under the wheels to prevent the machine from moving.
2 - 27
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TRANSPORTATION
The machine can be divided into parts for transportation, so when transportating the machine, please contact your
Komatsu distributor to have the work carried out.
LOADING AND UNLOADING

When loading or unloading the machine, mistaken operation may
bring the hazard of the machine tipping over or falling, so particular
care is necessary. Always observe the following.
Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of the road or cliff.
Always use ramps of adequate strength. Be sure that the ramps
are wide, long, and thick enough to provide a safe loading slope.
Take suitable steps to prevent the ramps from moving out of
position or coming off.
Be sure the ramp surface is clean and free of grease, oil, ice and
loose materials. Remove dirt from the tire of the machine. On
(1) Blocks
a rainy day, in particular, be extremely careful since the ramp (2) Ramp
surface is slippery. (3) Width of ramps: Same width as track
Run the engine at low speed and travel slowly. (4) Angle of ramps: 15°
Never correct your steering on the ramps. If necessary, drive off (5) Block
the ramps, correct the direction, then enter the ramps again.
When loading or unloading the machine to an embankment or platform, make sure that it has suitable width,
strength, and grade.
For machines equipped with a cab, always lock the door after boarding the machine. If this is not done, the door
may suddenly open during transportation.
Refer to "TRANSPORTATION (PAGE 3-142)".
SHIPPING
When shipping the machine on a trailer, do as follows.
The weight, transportation height, and overall length of the machine differ according to the work equipment, so
be sure to confirm the dimensions.
When passing over bridges or structures on private land, 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.
Lock the frame with the frame lock bar to prevent the machine from articulating.
For details of the shipping procedure, see "TRANSPORTATION (PAGE 3-142)" in the OPERATION section.
2 - 28
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BATTERY
BATTERY HAZARD PREVENTION

Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode.
Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions.
Do not use or charge the battery if the battery electrolyte level is below LOWER LEVEL line. This may cause an
explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to
UPPER LEVEL line.
When working with batteries, always wear protective eyeglasses and rubber gloves.
Never smoke or use any open flame near the battery.
If you spill acid on your clothes or skin, immediately flush the

area with large amount of water.
If acid gets into your eyes, flush them immediately with large
amount of water and seek medical attention.
Before working with batteries, turn the starting switch to OFF position.
As there is a hazard that sparks will be generated, always observe the followings.
Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or other
metal objects lying around near the battery.
Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last. Tighten the battery terminals securely.
Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take
it to a well-ventilated place, and remove the battery caps before charging it.
Tighten the battery caps securely.
Install the battery securely to the determined place.
2 - 29
.
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 observe the
following.
When starting with a booster cable, perform the starting
operation with 2 workers (1 worker sitting in the operator's seat
and the other working with the battery).
When starting from another machine, do not allow the nomal
machine and failed machine.
When connecting the booster cables, turn the starting switch
OFF position for both the normal machine and problem
machine. There is a hazard that the machine will move when the
power is connected.
Be sure to connect the positive (+) cable first when installing the
booster cables. Disconnect the negative (-) cable (ground side)
first when removing them.
When removing the booster cables, be careful not to let the
booster cable clips touch each other or to let the clips touch the
machine.
Always wear protective eyeglasses and rubber gloves when
starting the engine with booster cables.
When connecting a normal machine to a failed machine with
booster cables, always use a normal machine with the same
battery voltage as the failed machine.
For details of the starting procedure when using booster cables,
see "STARTING ENGINE WITH BOOSTER CABLE (PAGE
3-160)" in the OPERATION section.
2 - 30
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TOWING
WHEN TOWING
Serious injury or death could result if there is any mistake in the selection of wire rope or method of towing a disabled
machine.
For details of the procedure for towing, see the "METHOD OF TOWING MACHINE (PAGE 3-154)"
Always be sure to check carefully that the capacity of the wire rope used for towing is ample for the weight of the
towed machine.
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.
Always wear leather gloves when handling wire rope.
Never tow a machine on a slope.
During the towing operation, never stand between the towing
machine and the machine being towed.
Move the machine slowly and be sure not to apply any sudden
load on the wire rope.
Connect a wire rope to the part indicated with the arrow in the
figure at right.
2 - 31
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PRECAUTIONS FOR MAINTENANCE SAFETY
PRECAUTIONS FOR MAINTENANCE

WARNING TAG
Always attach the "DO NOT OPERATE" warning tag to the work
equipment control lever in the operator's cab to alert others that
you are performing service or maintenance on the machine.
Attach additional warning tags around the machine if necessary.
Warning tag Part No. 09963-03001
Keep this warning tag in the tool box while it is not used. If there
is no toolbox, keep the tag in the operation manual pocket.
If others start the engine, or touch or operate the work

equipment control lever while you are performing service or
maintenance, you could suffer serious injury or death.
KEEP WORK PLACE CLEAN AND TIDY

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances
that will cause you to slip. Always keep the work place clean the tidy to enable you to perform operations safely.
If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure 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 - 32
.
SAFETY PRECAUTIONS FOR MAINTENANCE
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE

Stop the machine on firm, level ground.
Select a place where there is no hazard of landslides, falling
rocks, or flooding.
Lower the work equipment completely to the ground and stop
the engine.
After stopping the engine, operate work equipment control lever

(1) 2 to 3 times fully to the RAISE and LOWER positions to
release the pressure inside the hydraulic circuit, then set work
equipment lock lever (2) to the LOCK position.
Turn parking brake switch (3) to the ON position to apply the

parking brake, then put blocks under the front and rear of the
tires.
2 - 33
.
Lock the front and rear frames with frame lock bar (4).
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent personal injury, do not perform maintenance with the engine running. If maintenance must be performed
with the engine running, perform the operation with at least 2 workers and observe the following.
1 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.
When performing 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.
Never drop or insert tools or other objects into the fan or fan belt.
Parts may break or be sent flying.
Set work equipment lock lever (1) to the LOCK position to

prevent the work equipment from moving.
Turn parking brake switch (2) to the ON position to apply the
parking brake.
Do not touch any control levers. If any control lever must be
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.
2 - 34
.
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 or
death.
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 property
damage. For this reason, always observe the following
precautions.
Do not disassemble the accumulator.
Do not bring it near open flame or dispose of it in fire.
Do not make holes in it, weld it, or use a cutting torch.
Do not hit or roll the accumulator, or subject it to any impact.
When disposing of the accumulator, the gas must be released.
Please contact your Komatsu distributor to have this work
performed.
PERSONNEL
Do not allow any unauthorized personnel into the area when servicing the machine. If necessary, employ a guard.
ATTACHMENTS
Appoint a leader before starting removal or installation
operations for attachments.
Place attachments that have been removed from the machine in
a stable condition so that they do not fall. And take steps to
prevent unauthorized persons from entering the storage area.
2 - 35
.
WORK UNDER THE MACHINE

When carrying out inspection and maintenance with the work
equipment raised, use strong support (1) that can fully withstand
the weight of the work equipment, and be sure to fix the stands in
position securely.
NOISE
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems. When carrying
out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers or ear plugs
while working.
PRECAUTIONS WHEN USING HAMMER

When using a hammer, pins may fly out or metal particles may be
scattered. This may lead to serious injury or death. Always
observe the followings.
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 serious personal injury or death.
Always wear protective eyeglasses and gloves.
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.
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 performed by a qualified welder and in a place equipped with proper equipment.
There is a hazard of gas, fire, or electrocution when performing welding, so never allow any unqualified personnel
to perform welding.
REMOVING BATTERY TERMINAL

When repairing the electrical system or when performing electrical welding, remove the negative (-) terminal of the
battery to prevent the flow of current.
2 - 36
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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 personal injury or death, so always observe the followings.
When carrying out inspection and maintenance of the pressure, release the pressure before starting. For details,
see "STOP ENGINE BEFORE CARRYING OUT MAINTENANCE (PAGE 2-33)". Do not carry out inspection or
replacement work with the circuit under pressure.
If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping
and hoses and for swelling in the hoses.
When perform inspection, wear protective eyeglasses and leather gloves.
There is a hazard that high-pressure oil leaking from small holes
may penetrate your skin or cause blindness if it contacts your
eyes directly. If you are hit by a jet of high-pressure oil and suffer
injury to your skin or eyes, wash the place with clean water, and
consult a doctor immediately for medical attention.
The pressure in the E.C.S.S. circuit is stored by an accumulator.
Do not remove the E.C.S.S. piping or components.
If it is necessary to remove them, please ask your Komatsu
distributor to carry out the removal operation.
HANDLING HIGH-PRESSURE HOSES

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury or property damage. If any loose bolts are found, stop work and tighten to the specified torque.
If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.

Damaged or leaking hydraulic fitting.
Frayed or cut covering or exposed reinforcement wire layer.
Covering swollen in places.
Twisted or crushed movable portion.
Foreign material embedded in covering.
WASTE MATERIALS
To prevent pollution, pay careful attention to the method of disposing of waste materials.
Always put oil drained from your machine in containers. Never
drain oil directly onto the ground or dump into the sewage
system, rivers, the sea, or lakes.
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 frostbite.
Never touch refrigerant.
2 - 37
.
COMPRESSED AIR
When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by
flying particles.
When using compressed air to clean elements or the radiator, always wear protective eyeglasses, dust mask,
gloves, and other protective equipment.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

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 relationship
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 (PAGE
4-13)".
The material of these components naturally changes over time, and repeated use causes deterioration, wear, and
fatigue. As a result, there is a hazard that these components may fail and cause serious personal injury or death.
It is difficult to judge the remaining life of these components from external inspection or the feeling when
operating, so always replace them at the specified interval.
Replace or repair safety critical parts if any defect is found, even when they have not reached the specified
replacement time.
2 - 38
.
SAFETY PRECAUTIONS WITH TIRES
PRECAUTIONS WITH TIRES

HANDLING TIRES
If tires or rims are handled mistakenly, there is danger that the tire
may explode or be damaged, or that the rim may fly off and cause
serious personal injury or death.
To maintain safety, always do as follows.
Maintenance, disassembly, repair, and assembly of the tires
and rims requires special equipment and special technology, so
always ask your Komatsu distributor to perform these
operations.
Always use the tires specified by Komatsu and maintain the
specified inflation pressure.
Suitable tire inflation pressure: see "HANDLING THE TIRES
(PAGE 3-140)"
When pumping up the tires, check that no other person is
standing near the tire, and install an air chuck with a clip that can
be secured to the air valve.
To prevent the tire inflation pressure from becoming too high,
measure the pressure from time to time with an air gauge while
pumping up the tire.
If the tire pressure goes down abnormally or the rim parts do not
fit the tire, there is a problem with the tire or rim parts. Always
contact your Komatsu distributor for repairs.
If the rim parts are not fitted properly when the tire is being
pumped up, there is danger that the rim parts may fly off, so set
up a protective fence around the tire, and do not stand directly
in front of the rim. Stand beside the tread when pumping up the
tire.
Do not adjust the tire inflation pressure immediately after traveling at high speed or performing operations under
heavy load.
Never perform welding or light a fire near the tire.
PRECAUTIONS WHEN STORING TIRES

Tires for construction equipment are extremely heavy, it may lead
to serious personal injury or death.
As a basic rule, store the tires in a warehouse which
unauthorized persons cannot enter.
If the tires must be stored outside, always erect a fence and put
up "No Entry" signs.
Stand the tire on level ground, and block it securely so that it
cannot roll or fall over if any person should touch it.
Do not lay the tire on its side. This will deform the tire and cause
it to deteriorate.
If the tire should fall over, do not attempt to stop it. Get out of the
way quickly.
2 - 39
.
.
3-1
.
GENERAL VIEW OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
(1) Bucket (8) Turn signal lamp

(2) Bell crank (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
(1) Gearshift lever stopper (13) Dimmer switch

(2) Rear wiper switch (14) Parking brake switch
(3) Front wiper switch (15) Cigarette lighter
(4) Gearshift lever (16) Load meter cancel switch (if equipped)
(5) Front switch panel (17) Kickdown switch
(6) Directional lever (18) Lift arm control lever
(7) E.C.S.S. (19) Hold switch
(electronic controlled suspension system) (20) Bucket control lever
switch (if equipped) (21) Load meter subtotal switch (if equipped)
(8) Horn button (22) Starting switch
(9) Hazard lamp switch (23) Right switch panel
(10) Machine monitor (24) Accelelator pedal
(11) Steering wheel (25) Right brake pedal
(12) Transmission cut-off switch (26) Steering tilt lock lever
(13) Lamp switch (27) Left brake pedal
(13) Turn signal lever (28) Work equipment lock lever
3-3
.
GENERAL VIEW OPERATION
MACHINE MONITOR
(1) Central warning lamp (21) Auto-greasing pilot lamp (if equipped)
(2) Brake oil pressure caution lamp (22) Joystick pilot lamp (if equipped)
(3) Engine oil pressure caution lamp (23) Directional selector pilot lamp (if equipped)
(4) Brake oil level caution lamp (24) Shift indicator
(5) Radiator coolant level caution lamp (25) Auto-shift pilot lamp
(6) Engine oil level caution lamp (26) Lockup pilot lamp (if equipped)
(7) Transmission oil filter clogging caution lamp (27) Shift hold pilot lamp
(8) Air cleaner clogging caution lamp (28) Shift lever position pilot lamp
(9) Parking brake pilot lamp (29) Torque converter oil temperature gauge
(10) Axle oil temperature caution lamp (30) Torque converter oil temperature caution lamp
(11) Cooling fan reverse rotation pilot lamp (31) Engine coolant temperature gauge
(12) Maintenance caution lamp (32) Engine coolant temperature caution lamp
(13) Battery electrolyte level caution lamp (if equipped) (33) Speedometer
(14) Battery charge circuit caution lamp (34) Turn signal pilot lamp
(15) Steering oil pressure caution lamp (35) Head lamp high beam pilot lamp
(16) Emergency steering pilot lamp (36) Meter display pilot lamp
(Machines equipped with emergency steering) (37) Hydraulic oil temperature caution lamp
(17) Character display portion (38) Hydraulic temperature gauge
(18) Output mode pilot lamp (power mode) (39) Fuel level caution lamp
(19) Preheating pilot lamp (40) Fuel gauge
(20) Semi auto digging pilot lamp (if equipped)
3-4
.
OPERATION GENERAL VIEW
SWITCH PANEL
RIGHT SWITCH PANEL FRONT SWITCH PANEL

(1) Transmission shift mode selector switch (14) Monitor panel mode selector switch 1
(2) Transmission cut-off set switch (15) Monitor panel mode selector switch 2
(3) Cooling fan reverse rotation switch (16) Front working lamp switch
(4) Emergency steering switch (17) Rear working lamp switch
(mhines equipped with emergency steering)
(5) Semi auto digging switch (if equipped)
(6) Remote positioner raise mode switch (if equipped)
(7) Directional selector actuation switch (if equipped)
(8) Auto-greasing switch (if equipped)
(9) Torque converter lock-up switch (if equipped)
(10) Remote positioner lower mode switch
(if equipped)
(11) Remote positioner raise/lower set switch
(if equipped)
(12) Starting switch
(13) Power mode selector switch
3-5
.
EXPLANATION OF COMPONENTS OPERATION
EXPLANATION OF COMPONENTS
The following is an explanation of devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.
MACHINE MONITOR
(A) Character display portion (E) Pilot display portion

(B) Emergency stop items (F) Meter display portion
(C) Caution items (G) Centralized warning lamp
(D) Inspection and maintenance items
NOTICE
When turning the starting switch to the ON position before starting the engine, the central warning lamp, caution lamps, and pilot
lamps light up for 2 seconds to check the system.
After the alarm buzzer sounds for 2 seconds, it goes off if the condition is normal.
The shift indicator display shows "88" for 2 seconds.
The indicator gauges and meters are actuated after the above system check is completed.
The character display shows "KOMATSU SYSTEM CHECK" for 3 seconds.
If the lamps do not light up, there is probably a failure or disconnection, so contact your Komatsu distributor for inspection.
3-6
.
OPERATION EXPLANATION OF COMPONENTS
TYPES OF WARNING
If an abnormality occurs on the machine, or if any switch or lever is
operated accidently, the machine 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 (PAGE 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 centralized warning lamp on the monitor and the caution lamp for the location of the abnormality light up. 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 coolant or lubricating oil overheat.
The centralized warning lamp on the monitor and the individual caution lamps light up. 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, in the following case, action code "E00" is displayed on character display (1).
When the machine has exceeded the travel speed limit.
When the work equipment lock lever is at the LOCK position and the EPC control lever is at any position other
than neutral. (Machines equipped with EPC)
INSPECTION AND MAINTENANCE

This warning is given if it is necessary to inspect and maintain wear parts, or if it is necessary to check the oil or
coolant level.
The individual caution lamp on the machine monitor lights up. At the same time, action code "E01" is displayed on
character display (1).
With this warning, the centralized warning lamp does not light up and the alarm buzzer does not sound.
CENTRALIZED WARNING LAMP

This display (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 display content and perform the specified action for that
item.
3-7
.
CHARACTER DISPLAY PORTION
(1) Service meter (4) Failure code display

(2) Clock (Machines equipped with load meter) (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, if there has been an excessive load on the machine, or if inspection and maintenance are
necessary, an action code is displayed to recommend suitable action.
When the time for replacing the filter or changing the oil is reached, 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.
The service meter advances while the engine is running, if the
machine is moving or not.
The meter advances by 1 for every hour of operation, regardless 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.
3-8
.
CLOCK
(Machines equipped with load meter)
This display (2) shows the time.
For details of the method of adjusting the time, see Section
"METHOD OF SETTING TIME ON CLOCK (PAGE 6-30)".
Even when the starting switch is OFF, the time can be displayed by
pressing the top () of monitor panel mode selector switch 1.
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 (PAGE 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
maintenance must be carried out, action code E00, E01, E02, or E03 is displayed on the character display in display
portion (3).
If different failures occur at the same time, the action code for the more serious problem is displayed.
The level of seriousness is as follows, starting with the most serious: E03, E02, E01, E00.
In the case of action codes E00, E02, and E03, the alarm buzzer sounds intermittently and the central warning lamp
lights up.
If action codes E00, E01, E02, or E03 are displayed on the character display, stop operations, check the content
of the display, and take the following action.
E03: When this code is displayed, stop the machine immediately,

check the failure code, and contact your Komatsu distributor
for repairs.
REMARK
"E03" is displayed on the top line of the character display and
"CHECK RIGHT NOW" and "CALL" are displayed in turn on the
bottom line for 3 seconds each.
The telephone number is displayed to the right of "CALL". If no
telephone number has been set, the display is blank. For
details of the method of inputting the telephone number, see
Section "INPUT METHOD FOR TELEPHONE NUMBER
(PAGE 3-33)".
3-9
.
E02: If this code is displayed, stop the machine and run the engine
under no load at a mid-range speed.
If an action code is still displayed after taking the necessary
action, check the failure code and contact your Komatsu
distributor for repairs.
REMARK
The top line of the character display displays "E02" and the bottom
line displays the condition of the machine related to overheating.
E01: When a failure occurs in the mechanical system, such as a

drop in the level of the engine coolant, the maintenance
location is displayed. If the maintenance caution lamp lights
up at the same time, inspect and perform maintenance of the
item indicated after completion of the day's work or when
changing shifts. If "MAINTENANCE" is displayed together
with E01, check the failure code and ask for repairs to be
carried out.
REMARK
"E01" is displayed on the top line of the character display and
"MAINTENANCE" or the part of the machine requiring inspection,
filling of fluid, or replacement is displayed on the bottom line.
E00: If an overrun related item is displayed, continue operations at

reduced engine speed and travel speed.
If an item related to the work equipment control lever is
displayed, return the lever to the HOLD position. (Machines
equipped with EPC)
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, 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.
The failure code is displayed with the first 6 digits on the left
of the top line of the character display.
The code displayed after the space on the right side of the
failure code indicates the controller that detected the failure
code.
The component causing the failure is displayed on the
bottom line of the character display.
Top right code Controller detecting failure code

MON Machine monitor
TM Transmission controller
ENG Engine controller
WRK Work equipment controller (if equipped)
2. Press the top (>) of monitor panel mode selector switch 2 (1) again.
If the condition is normal, the service meter is displayed for several seconds, then the display returns to the
action code.
If more than one failure has occurred at the same time, the next failure code is displayed.
3 - 11
.
FILTER, OIL REPLACEMENT TIME DISPLAY

After completion of the system check and when the starting switch
is in the ON position, if any filter or oil item is approaching the
replacement time, this display (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 FILTER,
OIL REPLACEMENT TIME (PAGE 3-32)".
REMARK
The top line of the character display shows the ID No. and item name for the item needing replacement; the
bottom line shows the time remaining until replacement and the total number of times the replacement has been
carried out.
If the replacement time has already passed, a minus (-) sign appears before the time.
After the display has been given for 30 seconds, it does not appear again until the starting switch is turned to the
ON position.
The message in the illustration above is not shown on the character display if an action code is being displayed.
If there are two or more items to be displayed, the display changes repeatedly every three seconds. If there are
more than 10 items, all the items are displayed once each, then the display returns to the 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
Replacement
Item Character display ID number
interval (H)
Engine oil 500 ENG OIL 01
Engine oil filter 500 ENG FILT 02
Fuel filter 500 FUEL FILT 03
Corrosion resistor 1000 CORR RES 06
Transmission oil 1000 TM OIL 12
Transmission oil filter 1000 TM FILT 13
Hydraulic filter 2000 HYD FILT 04
Hydraulic tank breather element 2000 HYD BREATH 05
Hydraulic oil 2000 HYD OIL 10
Axle oil 2000 AXLE OIL 15
3 - 12
.
REMARK
See the section below for details of the procedure for replacing the filter and oil.
Engine oil
"CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-51)"
Engine oil filter
"CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-51)"
Fuel filter
"REPLACE FUEL FILTER CARTRIDGE (PAGE 4-52)"
Corrosion resistor
"REPLACE CORROSION RESISTOR CARTRIDGE (PAGE 4-55)"
Transmission oil
"CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN
STRAINER (PAGE 4-53)"
Transmission oil filter
"CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN
STRAINER (PAGE 4-53)"
Hydraulic filter
"CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT (PAGE 4-56)"
Hydraulic tank breather element
"REPLACE HYDRAULIC TANK BREATHER ELEMENT (PAGE 4-58)"
Hydraulic oil
"CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT (PAGE 4-56)"
Axle oil
"CHANGE AXLE OIL (PAGE 4-59)"
3 - 13
.
EMERGENCY STOP ITEMS

CAUTION
If these lamps light up and the buzzer sounds, stop operations immediately and carry out inspection and maintenance of the
applicable location.
If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the lamp for
the location of the abnormality and the centralized 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
BRAKE OIL PRESSURE CAUTION LAMP

This lamp (1) lights up when the brake oil pressure goes below the
specified value.
During checks before starting (when the starting switch is turned to

the ON position but the engine is not started), the brake circuit is
not actuated while the engine is stopped, so the brake oil pressure
caution lamp and central warning lamp do not light up and the
alarm buzzer does not sound.
3 - 14
.
During operation (engine running)

If the brake oil pressure goes down during operation, the brake oil pressure caution lamp and centralized warning
lamp light up and the alarm buzzer sounds intermittently.
If the brake oil pressure caution lamp lights up, the footbrake may not work. Keep the parking brake applied to
prevent the machine from moving.
In addition, when the accumulator is being charged immediately after starting the engine, the brake oil pressure
caution lamp will light up, but the centralized warning lamp remains OFF and the alarm buzzer does not sound.
Keep the parking brake applied to prevent the machine from moving until the brake pressure becomes normal and
the brake oil pressure caution lamp goes out.
ENGINE OIL PRESSURE CAUTION LAMP

This lamp (2) lights up to warn the operator that the engine
lubricating oil pressure has dropped.

the ON position but the engine is not started), this monitor does not
light up.

If the engine lubricating oil pressure goes down during operation,
the engine lubricating oil pressure caution lamp and centralized
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 occurred in the charging circuit.

light up.

If an abnormality occurs in the charging circuit during operation,
the battery charge circuit caution lamp and centralized warning
lamp light up and the alarm buzzer sounds intermittently.
3 - 15
.
STEERING OIL PRESSURE CAUTION LAMP

(Red)
This lamp (4) lights up to warn the operator that the steering oil
pressure has dropped.

light up.
However, it lights up during the self-check of the emergency
steering.

If the steering oil pressure goes down during operation, the
steering oil pressure caution lamp and centralized warning lamp
light up and the alarm buzzer sounds intermittently.
3 - 16
.
CAUTION ITEMS
CAUTION
If these lamps light up, stop operations quickly and carry out the following action.
(1) Axle oil temperature caution lamp (4) Hydraulic oil temperature caution lamp
(2) Torque converter oil temperature caution lamp (5) Fuel level caution lamp
(3) Engine coolant temperature caution lamp
AXLE OIL TEMPERATURE CAUTION LAMP

This lamp (1) lights up to warn the operator that the brake oil
temperature has risen.

light up.

In continuous heavy-duty operations or when traveling long
distances downhill where the brake is used frequently, the axle oil
temperature becomes high. 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
OVERHEAT", so take the following action.
1. Release the accelerator pedal and move the gearshift lever down one range to reduce the travel speed.
2. Avoid using the brake.
1) Do not keep the brake pedal depressed continuously; use the brake only intermittently.
2) When using the left brake pedal, turn the transmission cut-off switch ON to carry out operations.
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.
3 - 17
.
TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP

This lamp (2) lights up to warn the operator that the torque
converter oil temperature has risen.

light up.

If the torque converter oil temperature rises, the torque converter
oil temperature caution lamp only will light up.
If the oil temperature rises further, the centralized warning lamp will
light up and the alarm buzzer will sound intermittently.
At the same time, "E02" is displayed on the top line of the character
display and "TC OVERHEAT" is displayed on the bottom line.
Stop the machine and run the engine under no load at a mid-range
speed until the lamp goes out.
ENGINE COOLANT TEMPERATURE CAUTION LAMP

This lamp (3) warns the operator that the engine coolant

light up.

If the engine coolant temperature rises, only the engine coolant
water temperature caution lamp will light up.
If the coolant temperature rises further, the centralized warning
lamp will light up and the alarm buzzer will sound intermittently.
At the same time as the centralized warning lamp lights up, the top
line of the character display displays "E02" and the bottom line
displays "ENGINE OVERHEAT", so stop the machine and run the
engine under no load at a mid-range speed until the lamp goes out.
3 - 18
.
HYDRAULIC OIL TEMPERATURE CAUTION LAMP

This lamp (4) lights up to warn the operator that the hydraulic oil

light up.

If the hydraulic oil temperature rises, the hydraulic oil temperature
caution lamp, the central warning lamp will light up, and the alarm
buzzer will sound intermittently.
display and "HYD OVERHEAT" is displayed on the bottom line.
Stop the machine and run the engine under no load at a mid-range
speed 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 27 liters (7.13 US gal).
If it lights up, check and add fuel and as soon as possible.
REMARK
Even if the caution lamp lights up, action code "E02" is not
displayed on the character display.
3 - 19
.
INSPECTION AND MAINTENANCE ITEMS

CAUTION
If these lamps light up, stop operations quickly and carry out the following action.
(1) Radiator coolant level caution lamp (5) Air cleaner clogging caution lamp
(2) Engine oil level caution lamp (6) Brake oil level caution lamp
(3) Battery electrolyte level caution lamp (if equipped) (7) Transmission oil filter clogging caution lamp
(4) 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.

the ON position but the engine is not started), this monitor lights up
if the coolant level in the radiator is low.
At the same time, the top line of the character display displays
"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.
3 - 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.

the ON position but the engine is not started), this monitor lights up
if the oil level in the engine oil pan is low.
"E01" and the bottom line displays "COOLANT 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 lit.
Stop the engine, check the oil level in the engine oil pan, and add oil.
BATTERY ELECTROLYTE LEVEL CAUTION LAMP

(if equipped)
This lamp (3) lights up to warn the operator that the battery
electrolyte level has gone down.

the ON position but the engine is not started), this monitor lights
up if the battery electrolyte level is low.
display and "BATTERY LEV LOW" is displayed on the bottom line,
so check the electrolyte level and add distilled water.

If the battery electrolyte level becomes too low, the battery
electrolyte level caution lamp will light up.
display and "BATTERY LEV LOW" is displayed on the bottom line,
so check the electrolyte level and add distilled water.
3 - 21
.
MAINTENANCE CAUTION LAMP
CAUTION
If the caution lamp lights up, repair the problem as soon as possible. If this is left as it is, it will lead to failure.
When the time for oil change is reached, this lamp (4) flashes or
lights up for approximately 30 seconds after completion of the
system check when the starting switch is at the ON position.
REMARK
The maintenance caution lamp flashes when there are less than
30 hours to the replacement time, and after the replacement time
has passed, it stays on.
For details of the items covered by filter and oil replacement, see "FILTER, OIL REPLACEMENT TIME DISPLAY
(PAGE 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 (PAGE 3-32)".
AIR CLEANER CLOGGING CAUTION LAMP

This lamp (5) lights up if the air cleaner element becomes clogged
when the engine is running.

light up.

The lamp lights up if the air cleaner element becomes clogged.
"E01" and the bottom line displays "AIR FILTER", so stop the
engine and clean or replace the element.
REMARK
It is possible to check the condition of clogging of the air cleaner with the dust indicator installed at the side of the
air cleaner.
3 - 22
.
BRAKE OIL LEVEL CAUTION LAMP

This lamp (6) is not used.
On this machine, the hydraulic oil is used for the brake oil.
TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP

This lamp (7) is not used.
3 - 23
.
PILOT DISPLAY PORTION

When the starting switch is ON, the pilot display lights up when the display items are functioning.
(1) Parking brake pilot lamp (9) Directional selector pilot lamp (if equipped)
(2) Cooling fan reverse rotation pilot lamp (10) Shift indicator
(3) Emergency steering pilot lamp (11) Auto-shift pilot lamp
(Machines equipped with emergency steering) (12) Lockup pilot lamp (if equipped)
(4) Output mode pilot lamp (power mode) (13) Shift hold pilot lamp
(5) Preheating pilot lamp (14) Shift lever position pilot lamp
(6) Semi auto digging pilot lamp (if equipped) (15) Turn signal pilot lamp
(7) Auto-greasing pilot lamp (if equipped) (16) Head lamp high beam pilot lamp
(8) Joystick pilot lamp (if equipped)
PARKING BRAKE PILOT LAMP

This lamp (1) lights up when the parking brake is applied.
3 - 24
.
COOLING FAN REVERSE ROTATION PILOT LAMP

This lamp (2) lights up when the direction of rotation of the cooling
fan is reversed.
At the same time, "COOLING FAN REVERSE" is displayed on the
character display.
REMARK
When the engine is running, even if the cooling fan reverse switch
is operated, the fan does not rotate in reverse.
In this case, the position of the switch and the actual direction of
rotation of the fan are different, so the cooling fan reverse rotation
pilot lamp flashes.
Return the switch to its original position or stop the engine and
operate the switch.
EMERGENCY STEERING PILOT LAMP

(Green)
(Machines equipped with Emergency steering)
This lamp (3) lights up when the emergency steering is being
actuated.
If the engine stops when the machine is traveling or an abnormality
occurs in the steering oil pressure circuit, and the machine is
traveling at a speed of more than 2 km/h (1.2 MPH), the emergency
steering is automatically actuated and the lamp lights up.
If the lamp lights up, move the machine immediately to a safe
place, stop the engine, and check the condition.
In addition, the lamp flashes if the emergency steering is actuated continuously for one minute.
At the same time, "E02 EMR S/T OVERRUN" is displayed on the character display, so move the machine
immediately to a safe place, stop the engine, and check the condition.
There is an emergency steering self-check function. For details, see "EMERGENCY STEERING SELF-CHECK
FUNCTION (PAGE 3-124)" in the OPERATION section.
OUTPUT MODE PILOT LAMP (POWER MODE)

This lamp (4) lights up when the power mode is selected.
Use the power mode selector switch to select the output mode.
3 - 25
.
PREHEATING PILOT LAMP

This lamp (5) lights up when the engine preheating electric heater
is actuated.
In cold weather, when the starting switch is turned to the ON
position, this lamp lights up. When the preheating is completed, it
goes out.
The preheating time differs according to the engine coolant
temperature.
SEMI AUTO DIGGING PILOT LAMP

(if equipped)
For details, see "HANDLING EPC WORK EQUIPMENT LEVER (PAGE 6-53)" in the ATTACHMENTS, OPTIONS
section.
AUTO-GREASING PILOT LAMP

(if equipped)
For details, see "HANDLING AUTO-GREASING SYSTEM (PAGE 6-38)" in the ATTACHMENTS, OPTIONS
section.
JOYSTICK PILOT LAMP

(if equipped)
For details, see "HANDLING JOYSTICK STEERING SYSTEM (PAGE 6-45)".
DIRECTIONAL SELECTOR PILOT LAMP

(if equipped)
This lamp (9) lights up when the directional selector switch
actuation switch on the right switch panel is turned ON. It shows
that it is possible to switch the direction of travel between
FORWARD and REVERSE with the directional switch at the side
of the lift arm control lever.
For details, see Section "CHANGING DIRECTION (PAGE
3-117)".
3 - 26
.
SHIFT INDICATOR
This indicator (10) indicates the transmission gear range (actual
travel speed range).
AUTO-SHIFT PILOT LAMP

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

(if equipped)
For details, see "HANDLING TORQUE CONVERTER LOCK-UP (PAGE 6-35)" in the ATTACHMENTS, OPTIONS
section.
SHIFT HOLD PILOT LAMP

This lamp (13) lights up when the shift hold is actuated.
3 - 27
.
SHIFT LEVER POSITION PILOT LAMP

This lamp (14) displays the transmission position of the gearshift
lever.
TURN SIGNAL PILOT LAMP

This lamp (15) flashes at the same time as the turn signal lamp
flashes.
REMARK
If there is a disconnection in the turn signal lamp, the flashing
interval becomes shorter.
HEAD LAMP HIGH BEAM PILOT LAMP

This lamp (16) lights up when the head lamps are set to high beam.
3 - 28
.
METER DISPLAY PORTION
(1) Torque converter oil temperature gauge (4) Fuel gauge

(2) Engine coolant temperature gauge (5) Speedometer
(3) Hydraulic oil temperature gauge (6) Meter display pilot lamp
TORQUE CONVERTER OIL TEMPERATURE GAUGE

This meter (1) indicates the torque converter oil temperature.
It should be in white range (A) during operations.
If it enters red range (B) during operations, caution lamp (C) inside
the torque converter oil temperature gauge will light up. At the
same time, the central warning lamp lights up and the alarm buzzer
sounds intermittently. In addition, "E02" is displayed on the top line
of the character display and "TC OVERHEAT" is displayed on the
bottom line.
Run the engine under no load at a mid-range speed and wait until
the indicator goes down to white range (A).
ENGINE COOLANT TEMPERATURE GAUGE

This meter (2) indicates the engine coolant 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 engine coolant temperature gauge lights up. At the
same time, the centralized 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).
3 - 29
.
HYDRAULIC OIL TEMPERATURE GAUGE

This meter (3) indicates the hydraulic oil temperature.
It should be in white range (A) during operations.
If it enters red range (B) during operations, caution lamp (C) inside
the hydraulic oil temperature gauge will light up. At the same time,
the central warning lamp lights up and the alarm buzzer sounds
intermittently. In addition, "E02" is displayed on the top line of the
character display and "HYD OVERHEAT" is displayed on the
bottom line.
Run the engine under no load at a mid-range speed and wait until
the indicator goes down to white range (A).
FUEL GAUGE
This meter (4) indicates the amount of fuel remaining in the fuel
tank.
F: Full tank
E: Fuel level is low
When the remaining amount of fuel goes below 27 liters (7.13 US
gal), caution lamp (A) inside the fuel gauge lights up.
If it lights up, check and add fuel.
SPEEDOMETER
This meter (5) indicates the travel speed of the machine.
The display unit is indicated on meter display pilot lamp (6).
It is also possible to display the engine speed by switching meter
(5).
If you wish to switch between the speedometer and tachometer,
please contact your Komatsu distributor to have it switched.
METER DISPLAY PILOT LAMP

This lamp (6) displays the unit for the travel speed or engine
tachometer.
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.
OTHER FUNCTIONS OF MACHINE MONITOR

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

Use this when checking the total distance that the machine has traveled.
1. Check that the character display is displaying the service meter or an action code. If there is any other display,
turn the starting switch OFF, then turn the starting switch ON again and wait for the service meter display or
action code display to appear.
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.
3 - 31
.
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 panel mode selector switch 1. It will

change to the display in the diagram on the right.
The bottom line shows two items: the replacement time on the
left and the total number of times the item has been replaced
on the right.
4. Press the (>) or (<) of monitor panel mode selector switch 2 to
display the item (filter or oil) which has reached the
replacement time.
5. Press the () of monitor panel mode selector switch 1. It will

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 monitor panel mode selector switch 1.
It will reset and return to the previous screen.
To abort, align the cursor with "NO", then press () of monitor
panel mode selector switch 1.
7. When resetting the replacement time for another item, use the procedure in Step 4. After completing, press (
) of monitor panel mode selector switch 1 twice or turn the starting switch OFF.
3 - 32
.
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.
display "TEL".
3. Press () of monitor panel mode selector switch 1. It will

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 to 9". To
leave a blank, select "*".
When the input value is decided, press () of monitor panel
mode selector switch 1. The cursor will move to the next
position.
5. Repeat the procedure in Step 4 until the last digit. At the last digit, press () of monitor panel mode selector
switch 1 to return to the previous screen.
If there is a mistake in the input or the input is to be stopped, press () of monitor panel mode selector switch
1 to return to the previous screen.
6. When completing the operation, press () of monitor panel mode selector switch 1 twice or turn the starting
switch OFF.
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.
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.
display "LGUAGE".
3. Press the () of machine mode panel selector switch 1. The

presently selected language is displayed.
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 monitor
panel mode selector switch 1.
mode selector switch 1 twice or turn the starting switch OFF.
3 - 34
.
METHOD OF ADJUSTING MONITOR BRIGHTNESS

Do as follows to adjust the brightness of the machine monitor.
display "BRIGHTNESS ADJUST".
3. Press the () of monitor panel mode selector switch 1.

"MONITOR PANEL" will be displayed on the bottom line and
it will be possible to adjust the brightness of the monitor.
The brightness can be adjusted for the overall monitor or for the
liquid crystal display only.
To adjust only the brightness of the liquid crystal display, press the
(>) or (<) of monitor panel mode selector switch 2 to switch the
display to "LCD PANEL".
4. Press the () of monitor panel mode selector switch 1. The

screen will change to the display shown on the right and it will
be possible to adjust the brightness.
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.
mode selector switch 1 twice or turn the starting switch OFF.
3 - 35
.
SWITCHES
3 - 36
.
(1) Starting switch (19) Room lamp switch

(2) Power mode selector switch (20) Rear heated wire glass switch
(3) Transmission shift mode selector switch (21) E.C.S.S.
(4) Transmission cut-off switch (electronic controlled suspension system)
(5) Transmission cut-off set switch switch (if equipped)
(6) Lamp switch (22) Emergency steering switch
(6) Turn signal lever (Machines equipped with emergency steering)
(6) Dimmer switch (23) Cooling fan reverse rotation switch
(7) Horn button (24) Directional selector switch (if equipped)
(8) Hazard lamp switch (25) Directional selector actuation switch (if equipped)
(9) Parking brake switch (26) Semi auto digging switch (if equipped)
(10) Front working lamp switch (27) Remote positioner raise mode switch (if equipped)
(11) Rear working lamp switch (28) Remote positioner lower mode switch
(12) Monitor panel mode selector switch 1 (if equipped)
(13) Monitor panel mode selector switch 2 (29) Remote positioner raise/lower set switch
(14) Kickdown switch (if equipped)
(15) Hold switch (30) Aftercooler tilt switch (if equipped)
(16) Front wiper switch (31) Torque converter lock-up switch (if equipped)
(17) Rear wiper switch (32) Load meter cancel switch (if equipped)
(18) Cigarette lighter (33) Load meter subtotal switch (if equipped)
STARTING SWITCH
This switch (1) is used to start or stop the engine.
OFF position
It is possible to insert and remove the starting switch key, all the
electric system switches are turned off, and the engine stops. In
addition, the parking brake is automatically applied.
ON position
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.
If the engine water temperature is below 7°C (44.6°F) when the engine is started, the preheating pilot lamp will light
up automatically and preheating will start.
The preheating time differs according to the water temperature when the engine is started.
If the preheating pilot lamp lights up, wait for it to go out, then turn the key to the START position.
START position
This is the engine-start position. Keep the key at this position during cranking. Immediately after starting the engine,
release the key. It will automatically return to the ON position.
3 - 37
.
MANUAL position
When starting in cold weather, set to this position if it is desired to extend the preheating time beyond the automatic
preheating time.
When the switch is released, it will return to the OFF position, so turn it immediately to the START position and start
the engine.
POWER MODE SELECTOR SWITCH

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

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

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

is a position selected by gearshift lever
L position: This is suitable for operations on flat ground and for
normal travel operations
M position: This is suitable for load and carry operations and
traveling up slopes of 3° to 6°
H position: This is suitable for load and carry operations and
traveling up slopes of more than 6°
If it is set to the L position when the work is mainly operations on flat ground, it is possible to shift up when the engine
speed is low. This is effective in reducing fuel consumption.
REMARK
For details of the manual shift, see "MANUAL SHIFT (PAGE 3-50)".
For details of the auto-shift, see "AUTOMATIC SHIFT (PAGE 3-51)".
3 - 38
.
TRANSMISSION CUT-OFF SWITCH
WARNING
When moving the machine off on an uphill slope, set the transmission cut-off switch to the OFF position, depress the accelerator
pedal while keeping the left brake pedal depressed, then gradually release the brake pedal and allow the machine to move. In this
way the machine can be prevented from traveling backwards.
Press this switch (4) to turn on and off the transmission cut-off
system.
When the switch is pressed, the pilot lamp lights up and the system
is turned ON. The transmission is shifted to neutral at the adjusted
brake pedal depression position.
Normally, keep the switch at the ON position.
For details of the method of adjusting the cut-off position, see

"ADJUSTING TRANSMISSION CUT-OFF POSITION (PAGE
3-122)" in the STOPPING MACHINE section.
Position (a): OFF
The left brake pedal acts in the same way as the normal brake (right brake pedal).
Position (b): ON
The left brake pedal acts in the same way as the normal brake, and at the same time, sets the
transmission to neutral.
REMARK
The brake pedal position where the cut-off system is actuated can be adjusted by using the transmission cut-off set
switch on the right switch panel.
TRANSMISSION CUT-OFF SET SWITCH
CAUTION
Apply the parking brake before adjusting the transmission cut-off position.
Turn this switch (5) ON to adjust the brake pedal position where the
transmission is automatically shifted to Neutral.
Position (a): ON
Cut-off position can be adjusted
When the switch is released, it automatically returns to its original

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

"ADJUSTING TRANSMISSION CUT-OFF POSITION (PAGE
3-122)" in the STOPPING MACHINE section.
3 - 39
.
LAMP SWITCH
This switch (6) is used to light up the front lamps, side clearance
lamps, tail lamps, and instrument panel.
Position (a): OFF
Position (b): Side clearance lamps, tail lamps, and instrument
panel light up
Position (c): Head lamps light up in addition to lamps at (b) position
REMARK
The lamp switch can be operated regardless of the position of the
lever.
TURN SIGNAL LEVER

This lever (6) is used to operate the turn signal lamp.
(a) position: LEFT TURN (Push lever FORWARD.)
(b) position: RIGHT TURN (Pull lever BACK.)
REMARK
When the lever is operated, the 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 (6) is used to switch the head lamps between high
beam and low beam.
Position (a): Low beam
Position (b): High beam
HORN BUTTON
When the horn button (7) in the center of the steering wheel is
pressed, the horn will sound.
3 - 40
.
HAZARD LAMP SWITCH
WARNING
Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for other machine
operators.
This switch (8) is used in emergencies, such as when the machine

breaks down and has to be parked on the road.
ON position: All turn signal lamps flash.
REMARK
When this switch is turned to the ON position, the turn direction
indicator lamps and turn indicator pilot lamp flash, and display lamp
(A) lights up at the same time.
PARKING BRAKE SWITCH
WARNING
Always apply the parking brake when leaving the machine or when parking it.
Even if the parking brake switch is turned ON, there is danger until the parking brake pilot lamp lights up, so keep the brake pedal
depressed.
NOTICE
Do not use the parking brake switch to apply the brake when traveling except in emergencies. The parking brake may be
damaged, resulting in a serious accident. Stop the machine first, then apply the parking brake.
If the parking brake has to be used as an emergency brake when the machine is traveling at high speed, ask your Komatsu
distributor to carry out inspection to check that there is no damage to the parking brake.
This switch (9) operates the parking brake.

Position (a): ON
The parking brake is applied, and the parking brake
pilot lamp lights up.
Position (b): OFF
The parking brake is released.
REMARK
When the parking brake is applied, the machine will not move off even if the directional lever is operated.
If the directional lever is placed at the F or R position with the parking brake still applied, the central warning lamp
will light up and the buzzer will sound.
Before starting the engine, turn the parking brake switch ON, then turn it OFF again.
3 - 41
.
FRONT WORKING LAMP SWITCH
WARNING
Always turn the working lamp off before traveling on public roads.
When turning the front working lamp ON, operate the lamp switch
to turn the side clearance lamp ON or the head lamp ON, then
operate this switch (10).
Position (a): Working lamp lights up
Position (b): Working lamp goes out
If position (a) is pressed, the pilot lamp will light up and the working
lamp circuit will be switched ON.
If the lamp switch is not at the ON position for the side clearance
lamp or head lamp, the working lamp will not light up.
REAR WORKING LAMP SWITCH
WARNING
Always turn the working lamp off before traveling on public roads.
When turning the rear working lamp ON, operate the lamp switch
to turn the side clearance lamp ON or the head lamp ON, then
operate this switch (11).
Position (a): Working lamp lights up
Position (b): Working lamp goes out
If position (a) is pressed, the pilot lamp will light up and the working
lamp circuit will be switched ON.
If the lamp switch is not at the ON position for the side clearance
lamp or head lamp, the working lamp will not light up.
MONITOR PANEL MODE SELECTOR SWITCH 1

This switch (12) is used to switch the function of the character
display.
position.
The basic operation is as follows.

Position ():
Press here to select (confirm) each mode or operation
Position ():
Press here to cancel each mode or operation
3 - 42
.
MONITOR PANEL MODE SELECTOR SWITCH 2

This switch (13) is used to switch the function of the character
display.
position.
The basic operation is as follows.

Position (>): Press here to go on to the next screen, or to move the
cursor forward, or to increase the number when
entering numerals
Position (<): Press here to go back to the previous screen, or to
move the cursor back, or to reduce the number when
entering numerals
KICKDOWN SWITCH
When the gearshift lever is in 2nd, if switch (14) on the head of the
lift arm control lever is pressed, the transmission will shift down to
1st.
Use this when you need to increase the drawbar pull in digging
operations.
If the transmission is in auto-shift, and the travel speed is below

12.5 km/h (7.8 MPH) in any speed range when traveling in either
forward or in reverse, the kick-down switch is actuated and it is
possible to shift down to 1st.
This makes it easy to carry out load and carry operations.
Even if the travel speed is more than 12.5 km/h (7.8MPH), this switch can be used to shift the transmission down.
Each time the kick-down switch is pressed, the speed range will shift down 1 range at a time (F4 -> F3 -> F2).
When the torque converter is in the lockup condition (if equipped), the lockup is canceled.
REMARK
When canceling the kick-down, operate the directional lever. In manual shift, the kick-down can be canceled by
operating the gearshift lever to any position other than 2nd. It is also possible to cancel the kick-down by turning
the starting switch OFF.
In auto-shift, if the travel speed becomes high after the kick-down, the gear will be shifted up by the auto-shift.
In auto-shift, when traveling at more than 25 km/h (15.5 MPH) in 3rd or at more than 35 km/h (21.7 MPH) in 4th,
even if the kick-down switch is pressed, the transmission will not shift down. This is to prevent overrun of the
engine.
3 - 43
.
HOLD SWITCH
To fix the speed range when traveling in automatic transmission,
press switch (15) at the side of the lift arm control lever knob. The
transmission will be fixed in the speed range displayed on shift
indicator (A) on the machine monitor and shift hold pilot lamp (B)
will light up.
When the switch is pressed again, the display goes out.
Use this function to select the desired speed range when traveling
up or down hills or when carrying out operations such as grading.
REMARK
When the torque converter is in the lock-up condition (if
equipped), the transmission cannot be fixed.
When canceling the shift hold, operate the directional lever or
gearshift lever or operate the transmission shift mode selector
switch to MANUAL. It is also possible to cancel the hold shift by
turning the starting switch OFF.
FRONT WIPER SWITCH

When rotary switch (A) of this switch (16) is turned, the front wiper
will move.
If push button (B) is pressed, washer liquid will be sprayed out onto
the front glass while the button is being pressed.
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 (17) 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
3 - 44
.
CIGARETTE LIGHTER
This is used to light cigarettes.
After cigarette lighter (18) is pushed in, it will return to its original
position after a few seconds, so pull it out and light your cigarette.
ROOM LAMP SWITCH

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

(if equipped)
When this switch (20) is pressed, electric current flows through the
heated wire glass at the rear and the mist is removed from the
glass.
Position (a): ON (removes mist from glass)
Position (b): OFF
3 - 45
.
E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) SWITCH

(if equipped)
WARNING
If the machine is traveling or the work equipment is raised, the moment the E.C.S.S. switch is turned ON, the work equipment
will move.
If operations are carried out with the E.C.S.S. switch at the ON position, the moment the E.C.S.S. is actuated, the work
equipment may move.
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.
NOTICE
Always stop the machine and lower the work equipment to the ground before operating the E.C.S.S. switch.
When carrying out inspection and maintenance, first lower the work equipment to the ground, then turn the E.C.S.S. switch OFF
before starting the inspection and maintenance operation.
When carrying out leveling work, turn the E.C.S.S. switch OFF.
This switch (21) is used to turn the E.C.S.S. ON and OFF.

Position (a): ON
The pilot lamp lights up and the E.C.S.S. is actuated.
Position (b): OFF
The E.C.S.S. is not actuated.
REMARK
The E.C.S.S. is a device that uses the hydraulic spring effect of an accumulator to absorb the vibration of the
chassis during travel and allows the machine to travel smoothly and at high speed.
When traveling in 1st, the E.C.S.S. is not actuated.
When the speed range is 2nd to 4th, and the travel speed becomes more than 5 km/h (3.1 MPH), the E.C.S.S.
is automatically actuated; when the travel speed goes below 3 km/h (1.9 MPH), it is automatically disengaged.
3 - 46
.
EMERGENCY STEERING SWITCH

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

position.
Actuate the emergency steering only in cases of emergency or when checking the function.
The time for operating the emergency steering continuously is a maximum of 60 seconds.
When using the emergency steering, travel at a speed of less than 5 km/h (3.1 MPH).
For details, see "EMERGENCY STEERING (PAGE 3-123)" in the OPERATION section.
COOLING FAN REVERSE ROTATION SWITCH

This switch (23) is used to rotate the cooling fan in the reverse
direction when cleaning the radiator.
Position (a): ON
The pilot lamp inside the switch and the cooling fan
reverse rotation pilot lamp on the machine monitor
light up. At the same time, "COOLING FAN
REVERSE" is displayed on the character display, and
the fan is set to rotate in reverse.
Position (b): OFF
The cooling fan is set to rotate in the normal direction.
Stop the engine before operating the switch.
Switching normal rotation -> reverse rotation: With the engine stopped, do as follows: Starting switch ON -> reverse
rotation switch ON -> check machine monitor -> starting switch
START -> fan reverse rotation
Switching reverse rotation -> normal rotation: Engine at low speed -> starting switch OFF -> starting switch ON ->
reverse rotation switch OFF -> starting switch START -> fan normal
rotation
For details, see "CLEAN FINS BY ROTATING COOLING FAN IN REVERSE (PAGE 4-29)" in the WHEN
REQUIRED section.
REMARK
When the engine is running, even if the switch is pressed, the direction of rotation of the fan does not change,
but the cooling fan reverse rotation pilot lamp on the machine monitor flashes.
Use the reverse rotation of the fan only for cleaning. For normal operations, rotate the fan in the normal direction.
If operations are carried out with the fan rotating in the reverse direction, the machine will not display its full
function and will tend to overheat.
3 - 47
.
DIRECTIONAL SELECTOR SWITCH

(if equipped)
This switch (24) is used to switch the direction of travel of the
machine between forward and reverse.
F Position: FORWARD
N Position: Neutral
R Position: REVERSE
Before operating this switch, check that the condition is as follows.
Directional lever is at N
Directional selector switch actuation switch is at ON
If the condition is not as above, the switch will not work.
For details, see "CHANGING DIRECTION (PAGE 3-117)".
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH

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

(if equipped)
section.
REMOTE POSITIONER RAISE MODE SWITCH

(if equipped)
section.
REMOTE POSITIONER LOWER MODE SWITCH

(if equipped)
section.
REMOTE POSITIONER RAISE/LOWER SET SWITCH

(if equipped)
section.
3 - 48
.
AFTERCOOLER TILT SWITCH

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

(if equipped)
For details of the torque converter lock-up, see "HANDLING TORQUE CONVERTER LOCK-UP (PAGE 6-35)" in
the ATTACHMENTS, OPTIONS section.
LOAD METER CANCEL SWITCH

(if equipped)
For details of the load meter, see "HANDLING LOAD METER (PAGE 6-3)" in the ATTACHMENTS, OPTIONS
section.
LOAD METER SUBTOTAL SWITCH

(if equipped)
For details of the load meter, see "HANDLING LOAD METER (PAGE 6-3)" in the ATTACHMENTS, OPTIONS
section.
3 - 49
.
CONTROL LEVERS, PEDALS
(1) Gearshift lever (5) Bucket control lever

(2) Directional lever (6) Lift arm control lever
(3) Gearshift lever stopper (7) Brake pedal
(4) Work equipment lock lever (8) Accelerator pedal
GEARSHIFT LEVER
This lever (1) changes the speed range of the transmission.
MANUAL SHIFT
This machine has a 4-FORWARD, 4-REVERSE speed
transmission.
Place the gearshift lever in a suitable position to obtain the desired
speed range.
1st and 2nd speeds are used for working.
3rd and 4th speeds are used for traveling.
However, when the gearshift lever stopper is being used, it is
impossible to shift to 3rd or 4th. Disengage the gearshift lever
stopper before trying to shift gear.
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th
3 - 50
.
REMARK
The length of the lever can be adjusted to 3 stages (positions (A),
(B), (C)). To adjust the length, remove the screw at the bottom of
the lever knob, slide the knob to the desired position, then tighten
the screw again.
(The lever is installed to position (B) when it is shipped from the
factory.)
AUTOMATIC SHIFT
Automatic gear shifting can be carried out in the 2nd through 4th
speed range of the 4 forward and reverse speeds depending on
the travel conditions.
Position (a): 1st
Position (b): 2nd
Position (c): 3rd
Position (d): 4th
The range of speeds during automatic gear shifting is determined

by the position of the gearshift lever as shown in the chart on the
right.
REMARK
The 1st position for the gearshift lever fixes the transmission in
1st. There is no automatic shifting of the transmission.
When shifting down from 2nd to 1st, press the kick-down switch
on the lift arm control lever.
If the transmission is in auto-shift and the travel speed is below
12.5 km/h (7.8 MPH) in any speed range when traveling in
either forward or in reverse, the kick-down switch is actuated
and makes it possible to shift down to 1st.
Even if the travel speed is more than 12.5 km/h (7.8 MPH), this
switch can be used to shift the transmission down. Each time
the kick-down switch is pressed, the speed range will shift down
one range at a time (when in 4th: F4 -> F3 -> F2; when in 3rd:
F3 -> F2).
3 - 51
.
To set to the desired speed range when traveling uphill or downhill,

or when carrying out grading, do as follows.
When fixing the speed range
Press the HOLD switch on the lift arm control lever.
The speed range is fixed at the speed range displayed on the
transmission indicator on the main monitor.
When shifting up or down from set speed range
Shift gear with the gearshift lever.
REMARK
When the transmission has been shifted down from 2nd to 1st with the kickdown switch, it will shift up from 1st to
2nd when the travel speed increases.
DIRECTIONAL LEVER
This lever (2) is used to switch the direction of travel of the machine
between forward and reverse.
When starting the engine, if the directional lever is not at the N
position, the engine will not start.
In this case, the central warning lamp will light up and the buzzer
will sound.
Return the gearshift lever to the N position and start the engine.
Position (a): FORWARD
Position N: NEUTRAL
Position (b): REVERSE
REMARK
The length of the lever can be adjusted to 3 stages (positions (A),
(B), (C)). To adjust the length, remove the screw at the bottom of
the lever knob, slide the knob to the desired position, then tighten
the screw again.
(The lever is installed to position (B) when it is shipped from the
factory.)
GEARSHIFT LEVER STOPPER

This stopper (3) prevents the gearshift lever from entering the 3rd
or 4th positions when working.
Position (a): Stopper actuated.
Position (b): Stopper released.
3 - 52
.
WORK EQUIPMENT LOCK LEVER
WARNING
Before standing up from the operator's seat, set the work equipment lock lever securely to the LOCK position. If the work
equipment lock lever is not at the LOCK position, and work equipment control lever (A) is touched by mistake, it may lead to
a serious accident.
If the work equipment lock lever is not placed securely at the LOCK position, the work equipment may move, and this may lead
to a serious accident or personal injury. Check that the lever is in the position shown in the diagram.
When pulling up or pushing down the work equipment lock lever, be careful not to touch work equipment control lever (A).
This lever (4) is a lock device for the work equipment control lever.
Push the work equipment lock lever down to lock it.
REMARK
This lever serves to shut off the hydraulic circuit for work
equipment. When it is kept at the LOCK position, the work
equipment does not move, even if work equipment control lever (A)
is operated.
BUCKET CONTROL LEVER

This lever (5) operates the bucket.
Position (a): TILT

When the bucket control lever is pulled further from
the TILT position, the lever is stopped in this position
until the bucket reaches the preset position of the
positioner, and the lever is returned to the HOLD
position.
Position (b): HOLD
The bucket is kept in the same position.
Position (c): DUMP
3 - 53
.
LIFT ARM CONTROL LEVER

This lever (6) is used to operate the lift arm.
NOTICE
Do not use FLOAT position when lowering the bucket. Use FLOAT position
when leveling, see "LEVELING OPERATIONS (PAGE 3-130)".
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.
BRAKE PEDAL
WARNING
When traveling downhill, always use the right brake pedal, and use the
braking force of the engine together with the brake.
Do not use the brake pedal repeatedly more than necessary. If the brake
is used too frequently, the brake will overheat. If this happens, the
brakes will not work, so this may lead to a serious accident.
Do not put your foot on this pedal unless necessary.
These pedals (7) operate the brakes.
RIGHT BRAKE PEDAL

The brake pedal operates the wheel brakes.
Use the brake pedal for normal braking operations.
LEFT BRAKE PEDAL

The left brake pedal operates the wheel brakes.
When the transmission cut-off switch is in the ON position, and if this brake pedal is depressed, wheel brakes are
applied and the transmission is set to the neutral position at the same time. If the transmission cut-off switch is at
OFF, the left brake pedal acts in the same way as the right brake pedal.
REMARK
When the accelerator is being used for operating the work equipment, always set the transmission cut-off switch to
the ON position and use the left brake pedal to slow or stop the machine.
3 - 54
.
ACCELERATOR PEDAL
This pedal (8) controls the engine speed and output.
The engine speed can be freely controlled between low idle and full
speed.
STEERING TILT LOCK LEVER

WARNING
Stop the machine before adjusting the tilt of the steering wheel. If this operation (adjustment) is carried out while the machine is
moving, it may lead to a serious accident or personal injury.
This lever is used to unlock and lock the steering column when
adjusting the position of the steering column to the front or rear or
up or down.
Pull the lever up, set the steering wheel to the desired position,
then push the lever down to lock the steering column securely in
position.
The amount of adjustment is as follows.
Up-down When at When moved up to

movement 0 mm (0 in) 40 mm (1.6 in)
0 - 105 mm 0 - 130 mm
Tilt amount
(0 - 4.1 in) (0 - 5.1 in)
NOTICE
Do not operate the lever (1) continuously by excessive force. The lever (1) may become loose or get out of angle. In this case,
please ask your Komatsu distributor to carry out repairs.
The bolts (2) and (3) on steering column are the left-hand screw.
If they are screwed counterclockwise, it is not a loosening direction
but a tightening direction (A).
3 - 55
.
CAP WITH LOCK

The fuel tank filler port and the hydraulic tank filler port (if equipped) are equipped with locks.
Use the starting switch key to open and close the cap.
METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE FUEL TANK FILLER PORT)
TO OPEN THE CAP

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

1. Screw the cap into place.
2. Turn the key counterclockwise and take the key out.
3 - 56
.
METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE HYDRAULIC TANK FILLER
PORT)
(if equipped)
TO OPEN THE CAP

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

1. Screw the cap into place.
2. Turn the starting switch key counterclockwise and take the key out.
3 - 57
.
FRAME LOCK BAR

WARNING
When carrying out maintenance or transporting the machine, always set the frame lock bar to LOCK position.
Always remove the frame lock bar for travel operations. If it is not removed, the steering wheel cannot be used for steering,
and this may lead to serious damage or injury.
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.
TOWING PIN
1. Insert towing pin (1) into hole (2) in the counterweight.
2. Use linch pin (3) to set so that the towing pin does not come
out.
Reverse this operation to remove the pin.
3 - 58
.
GREASE PUMP
The grease pump is stored inside the battery box at the rear of the
machine. After using it, wipe off all grease stuck to the outside of
the pump and then store it in the box.
It can be stored in either the left or right battery box.
CAB DOOR OPEN LOCK

When getting in or out of the operator's compartment, or when
operating with the door open, use this lock to hold the door in
position.
1. Push the door against catch (1) to lock it in position.
2. 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 lever (2)
up to release the catcher.
5. When closing the door after getting of the machine, push lever
(3) down to release the catcher.
CAB WINDOW OPEN LOCK CANCEL KNOB

Use this knob when you want to move the glass in the window of
the door up or down to open or close it.
Grip lock release knob (1), release the lock, then move the glass
down to a lower lock position. Release lock release knob (1).
When the glass is moved down, there are 3 stages for lock position
(A).
3 - 59
.
FUSE
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.
The fuses protect the electrical equipment and wiring from burning
out.
If the fuse becomes corroded, or white powder can be seen, or the
fuse is loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.
Loosen knob (1) at two places, then remove cover (2). The fuse
boxes are A and B.
FUSE CAPACITY AND NAME OF CIRCUIT
FUSE BOX A
Fuse
No. Name of circuit
capacity
(1) 10A Horn, air suspension
(2) 20A Transmission control
(3) 10A Parking brake
(4) 10A Emergency steering
(5) 20A Work equipment positioner
(6) 20A Rear heated wire glass
(7) 20A Wiper, washer
(8) 10A Rotating lamp (if equipped)
(9) 10A (KOMTRAX)
(10) 10A Backup lamp, brake lamp
(11) 20A Main lamp circuit
(12) 10A Right side clearance lamp
(13) 10A Left side clearance lamp
(14) 10A Right head lamp
(15) 10A Left head lamp
3 - 60
.
FUSE BOX B
Fuse
No. Name of circuit
capacity
(1) 20A Starting switch
(2) 10A Hazard lamp
(3) 10A Instrument panel A
(4) 10A Room lamp
(5) 10A Spare 1
(6) 20A Power mode selector motor
(7) 10A Turn signal indicator
(8) 20A Front working lamp
(9) 20A Rear working lamp
(10) 10A Instrument panel B
(11) 10A Car radio
(12) 10A Spare 2
(13) 10A DC-DC converter
(14) 20A Air conditioner A
(15) 20A Air conditioner B
SLOW BLOW FUSE

If the power does not come on when the starting switch is turned to
the ON position, there is probably a disconnection in the slow blow
fuse, so inspect and replace it.
The slow blow fuse is on the left side of the machine at the side of
the engine.
SLOW BLOW FUSE

(1)120A: Heater relay (electrical intake air heater)
120A: Main power
(2)40A: Fuel cut-off power source
(3) 30A: Battery power (starting switch, hazard)
30A: After cooler tilt power source (if equipped)
3 - 61
.
POWER OUTLET
NOTICE
There are 2 power sources: 12 V and 24 V
Check the voltage of the electrical equipment and select the appropriate power source.
Mistaken use, such as using 24 V as the power source for 12 V equipment, will cause failure of the equipment.
When using the electric power source, do not install any equipment which will exceed the maximum amperage.
When cigarette lighter (1) is removed, the lighter socket can be

used as a 24V power source.
Maximum amperage: 9A (216W)
Electric power source (2) can be used as a 12V power source.

Maximum amperage: 10 A (120 W)
3 - 62
.
AM/FM RADIO
(Machine equipped with cab) (if equipped)
(1) Power switch/Volume (6) Preset switch

(2) Tone control knob (7) Seek
(3) Display (8) Band selector switch
(4) Clock button/Displaying frequency (9) Tuning switch
(5) AST
POWER SWITCH/VOLUME
When this switch (1) is turned to the right, it clicks and the power is
turned on. If it is turned further, the speaker volume is adjusted.
3 - 63
.
TONE CONTROL KNOB

If this knob (2) is turned to the right, the high tone is emphasized;
if it is turned to the left, the high tone is reduced.
DISPLAY
This display (3) shows the radio reception frequency and the
operating mode.
CLOCK BUTTON/DISPLAYING FREQUENCY

When this button (4) is pressed, the display changes to the time.
If it is pressed again, it displays the frequency.
AST
When this button (5) is pressed, the preset stations are called up
in turn.
When the desired broadcasting station is reached, press the
button again to stop it.
If the button is kept pressed continuously for 2 seconds, it is set to
auto memory.
3 - 64
.
PRESET SWITCH
With this switch (6), each button can be preset to one station each
for FM and MW (AM). (For details of the method of presetting, see
Section "METHOD OF PRESETTING STATION (PAGE 3-67)".)
SEEK
When this switch (7) ("SEEK") is pressed, it automatically
searches for stations that can be received, and when it receives a
station, it stops.
BAND SELECTOR SWITCH

When this switch (8) ("BAND") is pressed, the band is switched
between FM and MW (AM).
The reception band and frequency are displayed on the display.
TUNING SWITCH
When the "TUNE" button  of switch (9) is pressed, the frequency
goes up; when the  button is pressed, the frequency goes down.
If it is kept pressed, the frequency changes continuously.
3 - 65
.
METHOD OF OPERATION
LISTENING TO RADIO
1. Turn radio power switch (1) ON.
2. "BAND" switch (2) is used to select MW (AM) or FM.
3. Use the preset switch or tuning switch (3) to select the station.
4. Adjust the volume and tone as desired.
5. To turn the radio OFF, turn VOL knob (1) to the left until a click
is heard.
METHOD FOR SELECTING STATION AUTOMATICALLY

When the "SEEK" switch is pressed, it moves up to higher
frequencies and when it finds a station that can be received, it
stops automatically.
METHOD FOR SELECTING STATION MANUALLY

When the TUNE button  is pressed, the frequency goes up;
when the  button is pressed, the frequency goes down. If it is
kept pressed, the frequency changes continuously.
3 - 66
.
METHOD OF PRESETTING STATION

1. Select the desired preset station.
Use the "BAND" button to select MW (AM) or FM, and use the
"TUNE" button to select the frequency of the broadcasting
station.
2. Decide the number of the button to be preset, and keep it
pressed for 2 seconds. The number of the button will be
displayed and the presetting is completed.
3. Repeat steps 1 to 2 to preset other broadcasting stations.
To change the setting of a preset switch to another station,
repeat steps 1 to 2.
If the battery is replaced or the power is switched off, all the
preset settings are deleted. Perform the presetting
operation again.
It is possible to preset 6 AM (MW) stations and 6 FM
stations.
METHOD OF USING AUTO MEMORY

If the "AST" button is pressed for 2 seconds, the broadcasting
stations that can be received in the area are called up in turn, and
the broadcasting stations are automatically saved in the preset
memory.
AUTOMATIC SWITCHING OF MONAURAL/STEREO RECEPTION

If the reception of the FM stereo broadcast being received is weak (when you are far from the broadcasting station
or are surrounded by hills), the radio is automatically switched from stereo to monaural to reduce the interference.
When the stereo broadcast becomes stronger, it automatically switches back to stereo broadcasting.
3 - 67
.
METHOD OF SETTING TIME

1. Turn the starting switch ON, then turn radio power source (1)
ON. If the display is showing the frequency, press the CLOCK
button to display the time.
2. To set the time, keep CLOCK button pressed and
Press the  button to change the minutes
Press the  button to change the hours
PRECAUTIONS WHEN USING

Stow the antenna when traveling in places with low overhead clearance.
To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during operation.
If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water
on the equipment.
Do not wipe the scales or buttons with solvent such as benzene or thinner. Wipe with a dry soft cloth. If the dirt
cannot be removed easily, soak the cloth with alcohol.
3 - 68
.
AM/FM RADIO-CASSETTE STEREO

(1) Power switch/volume (8) Cassette door

(2) Auto-store/preset scan button (9) Fast forward, rewind buttons
(3) Bass control knob (10) Preset buttons
(4) Treble control knob (11) Metal tape button
(5) Loudness button (12) Manual tuning buttons
(6) Time/radio display selector button (13) Seek tuning buttons
(7) Tape eject button (14) Band selector button
(A) Band display (E) Tape direction display

(B) Metal tape display (F) Preset channel display
(C) FM stereo reception display (G) Time/frequency display
(D) Loudness display
3 - 69
.
POWER SWITCH/VOLUME
Turn this knob (1) to the right until it clicks to turn the power on.
Turn it further to increase the volume.
AUTO-STORE/PRESET SCAN BUTTON

Use this button (2) to actuate the preset scan and auto-store
functions.
Auto-store
Each time this button is pressed for more than 2 seconds while
in radio reception, this auto-store function automatically starts to
search for the desired station within a receivable band, and
memorize the frequency in the preset memory. During this
scanning process, the frequency shown in the right side of
display continues to change. This indicates that each frequency
is memorized in the auto-store.
REMARK
The auto-store function cannot be used when the channel display
is flashing.
When the display is flashing, the preset scan function is being
used.
Preset scan
If this button is pressed for less than 0.5 seconds while in radio reception, programs from the 6 preset stations
in the same band will be broadcast 1 after another for 5 seconds each, starting from No. 1 through No. 6 stations
consecutively.
When the desired station is found, press the button again. This stops the preset scan tuning process and switches
to ordinary broadcasting. The same process will be repeated continuously until the button is pressed again.
BASS CONTROL KNOB

Turn this button (3) to the left to reduce the low tones; turn it to the
right to emphasize the low tones.
Direction (a): Low tone reduced
Direction (b): Low tone emphasized
3 - 70
.
TREBLE CONTROL KNOB

Turn this button (4) to the left to reduce the low tones; turn it to the
right to emphasize the high tones.
Direction (a): High tone reduced
Direction (b): High tone emphasized
LOUDNESS BUTTON
This button (5) is used when playing at low volume. It makes it
possible to hear more easily by emphasizing the low tone when the
low tones are weak.
Push button: Actuated (ON)
Push button again: Canceled (OFF)
TIME/RADIO DISPLAY SELECTOR BUTTON

This button (6) is used to switch between "Radio/tape display" and
"Time display".
Correcting the time

Press the button to set the time display.
(A) Correcting hour:
Keep DISP button pressed and press the bottom (H) of
TUNING button to correct the hour.
(B) Correcting minute:
Keep DISP button pressed and press the top (M) of TUNING
button to correct the minute.
3 - 71
.
TAPE EJECT BUTTON

This button (7) is used to stop the tape and to eject the cassette.
When this button is pressed, the tape is ejected and the radio
plays.
CASSETTE DOOR
Set the cassette with the exposed portion of the tape on the right
side and insert it through the cassette door (8).
FAST-FORWARD, REWIND BUTTONS

These buttons (9) are used to fast-forward or rewind the tape.
Fast-forward/rewind
If you press the button pointing in the same direction as the lit
arrow indicating the direction of play, the tape will be
fast-forwarded; if you press the button pointing in the opposite
direction, the tape will rewind.
To stop the tape, lightly press the button that is not locked. The
fast-forward or rewind operation will be canceled.
If the fast-forward and rewind buttons are pressed at the same
time, the tape will change sides.
PRESET BUTTONS
These buttons (10) are used to call up the broadcast station
frequencies preset in memory for each of buttons No. 1 to No. 6.
It is possible to preset 18 stations (FM: 12; AM: 6) with these
buttons.
3 - 72
.
METAL TAPE BUTTON

(used also for preset button No. 5)
This button (11) is used when playing a metal or chrome tape. This
button is also used for preset button No. 5. When it is pressed,
"MTL" appears on the display.
MANUAL TUNING BUTTONS

These buttons (12) are used for manual tuning.
When "TUN ∧" button is pressed, the frequency goes up; when
"TUN ∨" button is pressed, the frequency goes down. If the button
is pressed down and held, the frequency will change continuously.
SEEK TUNING BUTTONS

These buttons (13) are used to seek tuning.
When "SEEK UP" button is pressed, the search automatically
goes up; when "SEEK DN" button is pressed, the search
automatically goes down.
When the next station that can be received is found, it
automatically stops.
BAND SELECTOR BUTTON

When this button (14) is pressed, the band is switched between
FM1, FM2, and MW (AM). The band is shown on the display.
3 - 73
.
METHOD OF OPERATION
METHOD OF SETTING PRESET BUTTONS

It is possible to preset 6 MW (AM) stations and 12 FM stations (FM1: 6 stations, FM2: 6 stations).
REMARK
If you are playing the cassette, press the tape eject button to stop the tape.
METHOD OF AUTO PRESET

1. Use band selector button (1) to select MW (AM), FM1 or FM2.
2. Press auto-store/preset scan button (2) for less than 0.5
seconds.
3. The preset scan tuning function automatically searches for the
desired station within the same band and can memorize as
many as 6 stations in the preset memory.
METHOD OF MANUAL PRESET

2. Press manual tuning buttons (2) or seek tuning buttons (3).
3. Press preset button (4) of the number to be preset for 2
seconds while the frequency display is being shown on the
display. (The preset channel and frequency are displayed and
the presetting is completed).
4. Repeat the steps explained in Item 2 and 3 above to preset
other stations to the subsequent numbers.
5. If you want to preset a station in the other bands, follow the
steps explained in Item 1 through 4 above.
REMARK
Also, use Steps 2 and 3 when changing the setting of a preset
switch to another station.
When the power is disconnected, such as when the battery is
replaced, all the settings are deleted, so preset the stations
again.
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.
LISTENING TO RADIO
1. Turn the starting switch ON, then turn power switch (1) ON.
3. Select the station with the preset buttons (3).
REMARK
In case you do not promptly remember the number assigned to a
certain preset station, press auto-store/preset scan button (4) for
less than 0.5 seconds. The preset 6 stations will broadcast one
after another for 5 seconds each. When the desired station
broadcasts, press the button again and scan tuning stops.
4. If you want to tune in to a station that is not preset, use either

seek tuning button (5) or manual tuning button (6).
5. Adjust the volume, balance, and tone as desired.
6. When turning the radio OFF, turn power switch (1) to the left
until it clicks.
REMARK
To switch to the radio when listening to a cassette, press the cassette eject button to stop the tape.
If you insert a cassette when listening to the radio, the tape will start to play.
LISTENING TO CASSETTE TAPE

1. Turn the starting switch ON, then turn power switch (1) ON.
2. Set the cassette with the exposed portion of the tape on the
right side and push it past the cassette door. The tape will
automatically start playing.
If the arrow indicating the direction of play is pointing to the
right, the top side is being played; if the arrow is pointing to the
left, the bottom side is being played.
When the tape reaches the end, it is automatically reversed
and the other side starts to play.
3. When finished with the tape, press the cassette eject button to
eject the tape and automatically switch to the radio.
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REVERSING TAPE
When listening to the tape, press both FAST FORWARD,
REWIND buttons (A) and (B) at the same time lightly.
When this is done, the tape direction display will be reversed.

WARNING
If a voltage greater than the specified voltage is input, it may cause fire, electrocution, or other failure. Never input any voltage
other than the specified voltage.
Places inside the radio are under high voltage. Do not remove the cover.
Do not perform any modifications. This may cause fire, electrocution, or other failure.
If the sound cannot be heard, nothing is displayed, or any other problem occurs, turn off the power switch and ask your
Komatsu distributor to make repairs without delay.
Stow the antenna when traveling in places with low overhead clearance.
To ensure safety, adjust the sound to a level where it is possible to hear outside sounds during operation.
If water gets inside the speaker case or radio (auto tuning), it may cause a serious problem, take care not to let
water get in these items.
Do not wipe the scales or buttons with solvent such as benzene or thinner. Wipe with a dry soft cloth. If the dirt
cannot be removed easily, soak the cloth with alcohol.
NOTICE
Handling cassette tape
Clean the tape head approximately once a month with a commercially available head cleaning tape.
Do not leave the tape any place where it is exposed to direct sunlight, any place that is excessively dusty, or any place where
there is a magnetic field.
Do not use 120-minute tapes. The tape is thin and it easily gets caught up inside the machine.
If the tape is slack, it easily gets caught up inside the machine. Use a pencil to wind in the tape to remove any slack.
Do not use any cassette tape if the label has started to come off. It may cause defective rotation, or it may be impossible to get
the tape out of the machine.
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AIR CONDITIONER
By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it
possible to provide a pleasant working environment even on dusty jobsites.
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL
(1) Fan switch (4) FRESH/RECIRC selector switch

(2) Air conditioner switch (5) Temperature control switch
(3) Mode selector switch
FAN SWITCH
This switch (1) can be used to adjust the airflow in four stages.
It also acts as the main switch for the air conditioner. 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 airflow.
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AIR CONDITIONER SWITCH

This switch (2) is used to start or stop the cooling or dehumidifying
function.
When the fan switch is turned ON and the air conditioner switch is
pressed, the indicator lamp above the switch lights up. When the
switch is pressed again, the switch is turned OFF and the indicator
lamp goes out.
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, with your preferred air flow, to prevent dust from
entering the cab.
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TEMPERATURE CONTROL SWITCH

The temperature can be adjusted with this switch (5) by pressing
and holding the up or down button.
The temperature level indicator lamps light up to display the
temperature of the air coming from the vents.
The more the blue lamps light up, the lower the temperature is.
The color of the indicator lamp changes while the switch is being
pressed.
When the temperature reaches the desired level, release the
switch to set the temperature.
The settings for each mode are retained in memory even when the starting switch is turned OFF.
However, in the following cases, the settings must be reset.
When the machine has been out of use for more than 7 days
When the battery voltage is extremely low
When there has been abnormal interference from outside
When the fan switch is turned OFF (the setting is not kept in memory with only the air conditioner switch)
If the air conditioner is used in 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.
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METHOD OF OPERATION
Switch
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
Ventilation or
HI - LO OFF All blue FRESH FACE
pressurizing
When defrosting, set the temperature control switch so that all

lamps are red. This will improve 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 in cooling or dehumidification + heating mode for several minutes from time to time to prevent
the loss of the oil film in 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
warm up the inside of the cab, then turn the air conditioner switch on. The air conditioner will be run.
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.
COOL BOX
When the cooling is being used, this can be used for keeping drinks
and other things cool.
When the heating is being used, it can be used to keep things
warm.
When using the box, open the vent grill.
When not using the box, close the grill.
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 THE COOLING

If you smoke when using the air conditioner in the RECIRC mode, your eyes may start to itch or burn. Ventilate
the cab ever so often to remove the smoke.
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 (9 or 10.8°F) lower than the outside temperature) when you enter the cab.
Therefore, adjust the temperature to a suitable level.
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HANDLING AUTO AIR CONDITIONER

By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it
possible to provide a pleasant working environment even on dusty jobsites.
NAMES AND FUNCTIONS OF ITEMS ON CONTROL PANEL
(1) OFF switch (5) Auto switch

(2) Fan switch (6) RECIRC/FRESH selector switch
(3) Temperature control switch (7) Monitor panel
(4) Mode selector switch (8) Air conditioner switch
Even when the starting switch is turned OFF, the mode settings are retained in memory.
OFF SWITCH
This switch (1) turns the fan OFF.
When OFF switch (1) is pressed, the set temperature and air
flow displays on machine monitor (7) and the lamp at the top of
auto switch (5) go out.
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FAN SWITCH
Switch (2) is used to adjust the air flow.
The air flow can be adjusted to 6 levels.
Press the ∧ switch to increase the air flow; press the ∨ switch to
reduce the air flow.
When the fan switch is pressed, the lamp at the top of the auto
switch goes out.
During auto operation, the air flow is automatically adjusted.
TEMPERATURE CONTROL SWITCH

Switch (3) is used to control temperature inside the cab. The
temperature can be set between 18°C (64.4°F) and 32°C (89.6°
F).
Press the ∧ switch to raise the set temperature; press the ∨ s
witch to lower the set temperature.
The temperature is generally set at 25°C (77°F).
The temperature can be set in stages of 0.5°C (0.9°F).
<Monitor display and the function>
Monitor display Function
18.0°C (64.4°F) Max. cooling

18.5°C (65.3°F) to Adjusts temperature inside cab to set
31.5°C (88.7°F) temperature
32.0°C (89.6°F) Max. heating
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MODE SELECTOR SWITCH

Switch (4) is used to select the vents.
The vent position can be selected from five modes: FACE,
FACE/FOOT, FOOT, FOOT/DEF, DEF.
When this switch (4) is pressed, the display on monitor panel (7)
changes in turn, and the air blows out from the vents shown in
the display.
During automatic operation, the vents are automatically
selected.
AUTO SWITCH
With switch (5), the air flow, vents, and air source
(FRESH/RECIRC) are automatically selected according to the set
temperature.
This switch also acts as the air conditioner main switch.
When auto switch (5) is pressed, the lamp at the top of the auto
switch lights up and the auto mode is displayed.
When the fan switch is pressed, the lamp at the top of the auto
switch goes out.
Press switch (5), then use temperature control switch (3) to set
the temperature, and run the air conditioner under automatic
control.
When the control is switched from automatic operation to
manual operation, it is possible to operate the to change air flow,
vents, and air source (RECIRC/FRESH). When manual control
is used, lamp above the auto switch goes out.
RECIRC/FRESH SELECTOR SWITCH

Switch (6) is used to switch the air source between recirculation of
the air inside the cab and intake of fresh air from the outside.
When switch (6) is pressed, the lamp above the selector switch
lights up to show that air is being blown out.
During automatic operation, the selection of inside air (RECIRC)
and outside air (FRESH) is performed automatically.
Outside air is shut off and only air inside the cab is circulated.
RECIRC
Use this setting to perform rapid cooling of the cab or when outside air is dirty.
Outside air is taken into the cab.
FRESH
Use this setting to take in fresh air when performing demisting.
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MONITOR PANEL
The monitor panel shows the temperature setting (a), air flow (b),
and vent selection (c).
AIR CONDITIONER SWITCH

Switch (8) is used to turn the air conditioner (cooling,
dehumidifying, heating) ON or OFF.
When the auto switch or fan switch is turned ON and air
conditioner switch (8) is pressed, the air conditioner is switched
ON, the lamp at the top of the air conditioner switch lights up,
and the air conditioner starts. When it is pressed again to the
OFF position, the lamp at the top of the air conditioner switch
goes out.
Air conditioner cannot be operated while the fan is off.
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CONTROL METHOD
The air conditioner can be operated automatically or manually. Select the method of operation as desired.
AUTOMATIC WARMING-UP
1. Turn auto switch (5) ON.
The lamp above switch (5) lights up.
The set temperature (a) and air flow (b) are displayed on the
monitor.
2. Operate temperature control switch (3) to set to the desired

temperature. The air flow, vents, and air source
(RECIRC/FRESH) are selected automatically and the air
conditioner is run automatically to bring the temperature to the
set temperature.
STOPPING AUTOMATIC WARMING-UP

Press OFF switch (1). The display of the set temperature (a) and
air flow (b) on the monitor panel, and the lamps at the top of auto
switch (5) and air conditioner switch (8) go out, and the air
conditioner stops.
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MANUAL OPERATION
1. Press fan switch (2) and select the air flow. Check that the set
temperature (a) and air flow (b) are displayed on the monitor
panel.
2. Turn air conditioner switch (8) ON. Check that the lamp above
air conditioner switch lights up.
3. Press temperature control switch (3) to set the temperature

inside the cab.
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4. Press mode selector switch (4) and select the desired vent.
The display of the vent selection (c) on the monitor panel will
change according to the selection.
5. Press FRESH/RECIRC selector switch (6) and select

recirculation of the air inside the cab (RECIRC) or intake of
fresh air from outside (FRESH).
STOPPING MANUAL OPERATION

Press OFF switch (1). The display of the set temperature (a) and
air flow (b) on the monitor panel, and the lamps at the top of auto
switch (5) and air conditioner switch (8) go out, and the air
conditioner stops.

For the precautions when using the air conditioner, see "PRECAUTIONS WHEN USING (PAGE 3-81)" in the
section on the air conditioner in the OPERATION section.
INSPECTION AND MAINTENANCE

When carrying out inspection and maintenance of a machine equipped with air conditioner, see "MAINTENANCE
SCHEDULE CHART (PAGE 4-14)".
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HANDLING CAB WIPER
PREVENTING DAMAGE TO WIPER ARM BRACKET
NOTICE
When angling the wiper arm to the front, check that the wiper blade is
hanging free.
When angling the wiper arm to the front, such as when wiping the
glass clean, if the wiper arm is angled with the wiper blade locked
to the arm (the bottom of the blade is caught on the arm), abnormal
force is brought to bear on the mounting bracket and the bracket
may break.
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OPERATION OPERATION
OPERATION
CHECK BEFORE STARTING ENGINE, ADJUST
WALK-AROUND CHECK
Before starting the engine, walk around the machine and look at the underside of chassis for anything unusual like
loose bolts and nuts, leakage of fuel, oil and coolant. Also check the condition of the work equipment and the
hydraulic system.
Also check for loose wiring, play, and collection of dust at places that reach high temperature.
WARNING
Remove any combustible materials from around the battery, engine, muffler, turbocharger, or other high temperature engine
parts.
Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu
distributor.
If the machine is at an angle, reposition it level before checking.

Perform the following inspections and cleaning every day before starting engine for the day's work.
1. Check for damage, wear, play in work equipment, cylinders, linkage and hoses.
Check 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. Also check if there is any flammable
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 the engine.

Check that there is no oil leakage from the engine or coolant leakage from the cooling system. If any problem
is found, repair it.
4. Check for leakage of oil from transmission case, axle, hydraulic tank, hoses, joints.
Check that there is no oil leakage. If any abnormality is found, repair the leakage.
5. Check for oil leakage from the 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.
7. Check for damage and loose bolts on the handrail and steps.
Repair any damage and tighten any loose bolts.
8. Check for damage to gauges, lamps on the instrument panel and loose bolts.
Check for damage to the panel, gauges and lamps. If any problem is found, replace the parts. Clean off any dirt
on the surface. Tighten any loose bolts.
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.
OPERATION OPERATION
9. Check for loose air cleaner mounting bolts.

Check for the loose bolts. If loose, tighten them.
10. Check for loose battery terminals.

Tighten any loose terminal.
11. Check for damage to the seat belt and mounting clamps.
WARNING
Even if there appears to be no abnormality with the seat belt, replace it once every three years.
REMARK
The date of manufacture of the seat belt is marked on the belt at the
place indicated by the arrow in the figure 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 Nm {2.5 ± 0.5 kgm, 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.
12. Clean cab window.

Clean the cab window to ensure good visibility when operating the machine.
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.
OPERATION OPERATION
13. Inspect tires.
WARNING
If worn or damaged tires are used, they may burst and cause serious injury
or death.
To ensure safety, do not use the following tires.
Wear:
Tires with a tread grooves of less than 15% of that of a new tire
Tires with extreme uneven wear or with stepped-type wear
Damage:
Tires with damage that has reached the cords, or with cracks in the
rubber
Tires with cut or pulled cords
Tires with peeled (separated) surface
Tires with damaged bead
Leaking or improperly repaired tubeless tires
Deteriorated, deformed or abnormally damaged tires, which do not
seem usable
14. 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.
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OPERATION OPERATION
CHECK BEFORE STARTING

Always perform the procedures in this section before starting the engine each day.
CHECK MACHINE MONITOR

1. Turn the starting switch ON.
2. Check that all the monitors, gauges, and the central warning
lamp is lit for approx. 3 seconds and the alarm buzzer sounds
for approx. 1 sec.
If the lamps do not light up, there is probably a failure or
disconnection. Contact your Komatsu distributor for
inspection.
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OPERATION OPERATION
CHECK COOLANT LEVEL, ADD COOLANT
WARNING
Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check
the sub-tank.
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
If the cap is removed to check the coolant level in this condition, there is a hazard of burns. Wait for the temperature to go
down, then turn the cap slowly to release the pressure and remove it carefully.
CAUTION
When adding coolant, use the step and handrail provided. Support your body securely.
1. Open side door (1) of the engine hood on the right side of the
machine.
2. Look through inspection window (A) and check that the water
level is in the range between FULL and LOW on sub tank (2).
If the water level is low, open cover (3) and add water through
the filler port of sub tank (2) until it reaches the FULL level.
3. After adding coolant, tighten the cap securely.
4. If sub tank (2) is empty, check for leaks, then check coolant
level in the radiator. If the coolant level is low, add coolant to
the radiator, then add coolant to sub tank (2).
If the volume of coolant added is more than usual, check for

possible leakage.
Confirm that there is no oil in the coolant.
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OPERATION OPERATION
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until they
have cooled down before starting the work.
1. Open the inspection cover of the right side at the rear of the machine.
2. Take out dipstick (G) and wipe off the oil with cloth.
3. Fully insert dipstick (G) into dipstick pipe, then remove it.
4. The oil level should be between H and L marks on dipstick (G).
If the oil level is below L mark, add oil through oil filler port (F).
5. If the oil is above H mark, drain the excess oil from drain plug
(P), and check the oil level again.
6. If the oil level is correct, tighten oil filler cap (F) securely and
close the inspection window.
REMARK
Wait for at least 15 minutes, after stopping the engine, before
checking the oil level.
If the machine is at an angle, make it horizontal before
checking.
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OPERATION OPERATION
CHECK FUEL LEVEL, ADD FUEL
WARNING
When filling with fuel, do not add any more fuel after the fuel supply has automatically stopped. If too much fuel is added, there
is danger that the fuel may expand because of the rise in the ambient temperature and cause the fuel to overflow.
Spilled fuel may cause fire, so always wipe off any spilled fuel completely.
Fuel is highly flammable and a dangerous substance, so do not bring any fire or flame close.
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 on a full tank of fuel.
1. Turn the engine starting switch to the ON position and check

the fuel level with fuel level gauge (G).
After checking, turn the switch back to the OFF position.
2. After the day's work is finished, open cover (1) and refill fuel
through fuel filler port (F) until the fuel tank is full.
For details of the method for opening and closing the cap, see
"CAP WITH LOCK (PAGE 3-56)".
3. After adding fuel, tighten the cap securely.
Fuel capacity: 300 liters (79.26 US gal)
3 - 96
.
OPERATION OPERATION
CHECK ELECTRIC WIRING
WARNING
If the fuses frequently blow or if there are traces of short circuits in the electrical wiring, locate the cause and immediately
perform repairs, or contact your Komatsu distributor for repairs.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash
the battery cap to clean the breather hole.
Check for damage, wrong fuse capacity, and any sign of disconnection or short circuit in the electric wiring. Also,
check and tighten any loose terminals.
Particularly, check the wiring of the "battery", "starting motor" and "alternator" carefully.
When checking around the battery, make sure there is no accumulation of flammable material. Remove all
flammable material.
Consult your Komatsu distributor for investigation and correction of the cause.
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.
CHECK BRAKE PEDAL

Drive the machine forward and check the effect of the brakes.
If there is any problem in the actuation of the brakes, contact your Komatsu distributor to have the brakes adjusted.
CHECK INFLATION PRESSURE OF TIRES

Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work.
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. See Section "HANDLING THE TIRES
(PAGE 3-140)" for details.
CHECK HORN
Failures may occur at interval shorter than the periodical replacement interval of "2 years or 4000 hours".
Operate the horn switch and check that the horn sounds normally, or its sound quality is normal.
If there is any abnormality, ask your Komatsu distributor for the inspection and repair.
3 - 97
.
OPERATION OPERATION
ADJUSTMENT
SEAT ADJUSTMENT
WARNING
When adjusting the position of the operator's seat, always set the work equipment lock lever to LOCK position to prevent any
accidental contact with the control levers.
Always adjust the operator's seat before starting each operation or when the operators change shift.
When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can
be fully depressed.
DELUXE SUSPENSION SEAT

(A) Fore-and-aft adjustment
Pull lever (1) up, set the seat to the desired position, then release
the lever.
Fore-and-aft adjustment: 160 mm (6.3 in)
(16 mm (0.6 in) x 10 stages)
(B) Adjusting seat angle

Move lever (2) up and push down on the rear of the seat to tilt it
backward.
Move lever (2) down and push down on the front of the seat to tilt
it forward.
Adjustment range: 13 deg. (Front tilt, rear tilt: 4 stages each)
(C) Setting seat for operator's weight

Turn grip (3) to adjust the strength of the suspension.
Adjustment range: (Target) 50 to 120 kg (110 to 265 lb)
(D) Adjusting backrest angle

Move lever (4) up and move the backrest to the front or rear.
Adjustment range: Front 66 degrees (3 degrees x 22 stages)
Rear 72 degrees (3 degrees x 24 stages)
NOTICE
If the backrest is reclined too far, the backrest may hit the rear glass, so use it in a position where it does not contact the glass.
When reclining the seat fully to take a rest, set the seat in the following position.
Fore-and-aft adjustment: Max. front position
Up-down adjustment: Max. height
Seat angle adjustment: Horizontal or fully tilted
Reclining adjustment: Fully tilted backward 36 degrees (12 stages)
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OPERATION OPERATION
(E) Seat height adjustment

Move lever (2) up/down, then move the seat up or down as desired. Since lever (2) is also used for adjusting seat
angle, set the seat to the desired height while adjusting the angle.
Adjustment range: 60 mm (2.4 in)
(F) Adjusting headrest height

Move the headrest up and down to the desired height.
Adjustment range: 50 mm (2.0 in)
(G) Adjusting headrest angle

Rotate the headrest to the front or rear.
(H) Adujusting armrest angle

Adjust angle of armrest by rotating knob (5) (left side only).
Adjustment range: 30 degrees (forward tilt: 25 degrees, backward tilt:5 degrees)
Also, when armrest is turned, it will spring up. (Both left and right sides)
LUMBAR SUPPORT TYPE SEAT
NOTICE
When pulling up levers (2) and (3), be careful not to pull up the switch box at the front by mistake. There is danger that the
switch box may be damaged.
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 - 99
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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 to 130 kg (110 to 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)
(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
3 - 100
.
OPERATION OPERATION
REMOVAL AND INSTALLATION OF HEADREST

(Lumbar support type only)
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 headrest
can be removed.
INSTALLATION
1. Insert the bars into the holes in the top of the seat and push
down.
3 - 101
.
OPERATION OPERATION
ADJUST SEAT BELT

Always wear the seat belt.
WARNING
Before fastening the seat belt, check that there is no abnormality in the belt-mounting bracket or mounting of the belt. If the belt
is worn or damaged, replace it.
Fasten the seat belt before starting operations.
Always wear the seat belt during operations.
Make sure that the left and right belts are not twisted when fastening the seat belt.
FASTENING AND REMOVING BELT

Fasten the belt so that it is tight without being too tight.
1. Sit on the seat, depress the brake pedal fully, and adjust the
seat so that your back is pressed against the backrest.
2. After adjusting the seat position, adjust tether belt (1). Tense
the tether belt and install it when there is no one sitting on the
seat.
3. 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.
4. When removing the belt, press the red button in buckle (2) to free the belt.
Fasten the 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 front, mid-point of your body.
ADJUST BELT LENGTH

To make belt shorter: Pull the free end of the tether belt.
To make belt longer: Set the fixed end of the tether belt at 90
degrees to the holder, and pull.
3 - 102
.
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 ANGEL OF LEVER STAND

Operate lock lever (1) with your left hand to the FREE position, grip
the wrist rest with your right hand, tilt lever stand (2) to the front or
rear, then return lock lever (1) to the LOCK position.
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.
3 - 103
.
OPERATION OPERATION
OPERATIONS AND CHECKS BEFORE STARTING ENGINE

WARNING
When starting the engine, check that the work equipment lock lever are placed securely at the LOCK position. If the work
equipment control lever is touched by accident when the engine is started, the work equipment may move unexpectedly and
cause serious injury or damage.
1. Check that parking brake switch (1) is at the ON position.
2. Check that directional lever (2) is at N position.
REMARK
If directional lever (2) is not set to the N position, the engine will not
start.
3 - 104
.
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.
1) Check that the work equipment control lever is at the
HOLD position, then set the work equipment lock lever to
the FREE position.
2) Operate the work equipment control lever to lower the
bucket to the ground.
3) Check that the work equipment control lever is at the
HOLD position, then set the work equipment lock lever to
the LOCK position.
4. Check that work equipment lock lever (3) is at the LOCK
position.
5. Insert the key in starting switch (4), 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 machine monitor does not light up, there is probably a
failure or disconnection. Contact your Komatsu distributor for
inspection.
In addition, after all the monitors, gauges, and central warning
lamp light up, a self check is carried out to check that the
emergency steering function works properly. For details, see
"EMERGENCY STEERING SELF-CHECK FUNCTION
(PAGE 3-124)" in the OPERATION section.
3 - 105
.
OPERATION OPERATION
STARTING ENGINE
NORMAL STARTING
WARNING
Sit down in the operator's seat before starting the engine.
Do not attempt to start the engine by short-circuiting the engine starting
circuit. Such an act may cause serious injury, death or fire.
Check that there are no persons or obstacles in the surrounding area,
then sound the horn and start the engine.
Exhaust gas is toxic. When starting the engine in confined spaces, be
particularly careful to ensure good ventilation.
NOTICE
Do not accelerate the engine suddenly before completing the
warming-up operation.
Do not keep the starting motor rotating continuously for more than 20
seconds.
If the engine does not start, wait for at least 2 minutes before trying to
start the engine again.
1. Turn the key in starting switch (1) to the ON position.

Preheating will automatically start and preheating pilot lamp (2)
will light up.
If the engine water temperature is above 7°C (44.6°F), there is

no need to carry out preheating, so the engine can be started
even if preheating pilot lamp (2) does not go out.
REMARK
Normally, it is enough to carry out only the automatic preheating
operation. If it is desired to extend the preheating time, turn the key
in starting switch (1) to the MANUAL position to make it possible to
carry out preheating manually.
When extending the preheating time, keep it to a maximum of 45
seconds.
3 - 106
.
OPERATION OPERATION
The preheating time varies according to the engine coolant

Water temperature
temperature when the engine is started. Preheating time
when starting
to 7°C
The table on the right gives a guide to the preheating time (sec) in -
(to 44.6°F)
cold weather.
7°C to -0°C 10 seconds to
The preheating time is set to approx. 12 seconds when the engine
(44.6°F to 32°F) 17 seconds
water temperature is 0°C (32°F).
-0°C to -10°C 17 seconds to
(32°F to 14°F) 26 seconds
REMARK
The preheating time is set to give priority to ease of starting, but if
(14°F to -4°F) 36 seconds
the black smoke is considered to be a problem, it is possible to start
the engine before the preheating pilot lamp goes out by turning the
(-4°F to -22°F) 45 seconds
key in starting switch (1) to the START position.
2. When preheating pilot lamp (2) goes out, turn the key in
starting switch (1) to the START position.
3. Depress accelerator pedal (3) lightly until the engine starts,

then hold it in position.
4. The starting motor will continue to turn and the engine will start.
Keep the key in starting switch (1) at the START position to
keep the starting motor running until the engine starts.
REMARK
In low temperatures, to ensure lubrication of the engine and to
improve the durability, no fuel is supplied to the engine for 3
seconds after the key in starting switch (1) is turned to the START
position, so the engine will not start during this time.
Therefore, keep the key in starting switch (1) at the START position
to keep the starting motor running until the engine starts.
5. After the engine starts, release the key in starting switch (1).
The key will automatically return to the ON position.
REMARK
Keep the accelerator pedal depressed after the engine starts up,
until engine warming-up run is finished. Do not step on the pedal
to the full stroke.
3 - 107
.
OPERATION OPERATION
STARTING IN COLD WEATHER

WARNING
Sit down in the operator's seat before starting the engine.
Do not attempt to start the engine by short-circuiting the engine starting
circuit. Such an act may cause serious injury, death or fire.
Check that there are no persons or obstacles in the surrounding area,
then sound the horn and start the engine.
Exhaust gas is toxic. When starting the engine in confined spaces, be
particularly careful to ensure good ventilation.
NOTICE
Do not suddenly accelerate the engine before the warming-up operation
is completed.
It takes some time to start up the engine when the machine is left unused for more than half a day in the ambient
temperature of approx. -20°C (-4°F). In that case, use the engine starting switch and accelerator pedal in the
following manner.
1. Turn the key in starting switch (1) to the ON position.

Preheating will automatically start and preheating pilot lamp (2)
will light up.
REMARK
Normally, the automatic preheating is sufficient, but if it is desired
to extend the preheating time, turn the key in starting switch (1) to
the MANUAL position to make it possible to carry out extended
preheating.
The table shown below gives a guide to preheating time.

Water temperature
Preheating time
when starting
The pre-heating time in cold areas changes according to the water
to 7°C
temperature when starting the engine. -
(to 44.6°F)
The preheating time is set to approx. 17 seconds when the engine
7°C to -0°C 10 seconds to
water temperature is 0°C.
(44.6°F to 32°F) 17 seconds
REMARK (32°F to 14°F) 26 seconds
The preheating time is set to give priority to ease of starting, but if
the black smoke is considered to be a problem, it is possible to start
(14°F to -4°F) 36 seconds
the engine before the preheating pilot lamp goes out by turning the
key in starting switch (1) to the START position.
(-4°F to -22°F) 45 seconds
3 - 108
.
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.
REMARK
In low temperatures, to ensure lubrication of the engine and to
improve the durability, no fuel is supplied to the engine for 3
seconds after the key in starting switch (1) is turned to the START
position, so the engine will not start during this time.
Therefore, keep the key in starting switch (1) at the START position
to keep the starting motor running until the engine starts.
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.
2) If the engine fails to start up even after running the engine starting motor for about 20 seconds, stop the
engine starting motor once (release the engine starting switch key), and try the same process again after
a pause for a minute or so.
3) If the engine still fails to start up after the second attempt, try the same process for the third time after a pause
for a minute or so.
6. 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.
7. 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 - 109
.
OPERATION OPERATION
OPERATIONS AND CHECKS AFTER STARTING ENGINE

WARNING
Emergency stop
If the operation is abnormal or any other trouble occurs, turn the key in the starting switch to the OFF position.
If the work equipment is operated without warming up the machine sufficiently, the response of the work equipment to the
movement of the control lever will be slow. The work equipment may not move as the operator desires. Follow all warm-up
procedures. Particularly in cold areas, make sure to warm up the machine properly.
BREAKING-IN THE MACHINE

CAUTION
Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe
conditions at the beginning can adversely affect the performance and shorten the machine life.
Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
During break-in operations, follow the precautions described in this manual.
Idle the engine for 5 minutes after starting it up.

Avoid operation with heavy loads or at high speeds.
Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and
sudden changes in direction.
NORMAL OPERATION
After the engine starts, do not start operating the machine immediately. First, perform the following operations and
checks.
NOTICE
Do not suddenly accelerate the engine before the warming-up operation is
completed.
Do not run the engine at low idle or high idle continuously for more than 20
minutes.
If it is necessary to run the engine at idle, 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 approximately 5 minutes.
To warm up the hydraulic oil in cold areas, do as follows.
3 - 110
.
OPERATION OPERATION
2. After completing the warming-up operation, check that the

engine rotation is smooth, then check that the work equipment
control lever is at the HOLD position and set work equipment
lock lever to the FREE position.
3. Operate the bucket control lever to the TILT position and return
it to the HOLD position repeatedly to warm up the hydraulic oil.
Relieve the circuit at the TILT position for a maximum of 10
sec.
This brings the oil to the relief pressure and makes it quicker
warm up the oil.
4. After carrying out the warming-up operation, check that the
gauges and caution lamps are normal.
If there is any abnormality, carry out maintenance or repair.
Run the engine under a light load until engine water
temperature gauge (2) and torque converter oil temperature
gauge (3) are in the green range.
5. Check for abnormal exhaust gas color, noise, or vibration. If
any problem is found, contact your Komatsu distributor.
REMARK
The rotating speed of the cooling fan differs according to the following conditions, but this does not indicate any
abnormality.
The cooling fan speed increases when the hydraulic oil temperature, engine coolant temperature, or transmission
oil temperature are high.
However, when the cooling fan is rotating in reverse, it rotates at a fixed speed proportional to the engine speed,
regardless of any oil or coolant temperature.
3 - 111
.
OPERATION OPERATION
STOPPING ENGINE
NOTICE
If the engine is abruptly stopped before it has cooled down, engine life may
be greatly shortened. Consequently, do not abruptly stop the engine apart
from an emergency.
In particular, if the engine has overheated, do not abruptly stop it but run
it at medium speed to allow it to cool gradually, then stop it.
1. Run the engine at Low idle (MIN) for approximately 5 minutes

to cool down gradually.
2. Turn the key of starting switch (1) to OFF position to stop the
engine.
3. Remove the key from starting switch (1).
3 - 112
.
OPERATION OPERATION
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE

WARNING
Always remove the frame lock bar for travel operations. If it is not removed, the steering wheel cannot be used for steering,
and this may lead to serious damage or injury.
When moving the machine off, check that the area around the machine is safe, then sound the horn before starting.
Do not allow people to get near the machine.
Clear the machine's travel path of any obstacle.
Pay a particular attention to the blind spot at the rear of the machine, when traveling the machine in reverse.
When starting the machine off up a slope, set the transmission cut-off switch to the OFF position, depress the left brake pedal.
Then depress the accelerator pedal and gradually release the brake pedal to start the machine off. This makes it possible to
prevent the machine from rolling back.
MOVING THE MACHINE

1. Check that caution lamp (1) is not lit.
3 - 113
.
OPERATION OPERATION
2. Check that the bucket control lever (2) and lift arm control lever
(3) is at the HOLD position, then set the work equipment lock
lever (4) to the FREE position.
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 right brake pedal (5) and turn parking brake switch (6)
to the OFF (RELEASE) position to release the parking brake.
Keep right brake pedal (5) depressed.
REMARK
If the parking brake is still actuated when parking brake switch (6)
is at the OFF (RELEASE) position, turn the parking brake switch
ON, then turn it OFF again.
5. Set gearshift lever (7) to the desired position.
6. Set directional lever (8) to the desired position.
Check that the backup alarm sounds when the directional

lever is set to REVERSE. If the backup alarm does not
sound, contact your Komatsu distributor for repairs.
3 - 114
.
OPERATION OPERATION
7. Release right brake pedal (5), then depress accelerator pedal

(9) to move the machine off.
REMARK
When moving the machine off on a hill, turn transmission cut-off
switch (10) OFF, depress left brake pedal (11), operate the
gearshift lever to the low speed range, then depress accelerator
pedal (9) and gradually release left brake pedal (11) to let the
machine move off. This makes it possible to prevent the machine
from rolling back.
3 - 115
.
OPERATION OPERATION
CHANGING GEAR SPEED

WARNING
When traveling at high speed, do not shift gear suddenly. Use the brake to
reduce the travel speed before shifting gear.
Shift gear as follows.

Move the gearshift lever (1) to the desired position to shift gear.
When carrying out digging or loading operations, the operation is
carried out in 1st or 2nd, so use the gearshift lever stopper.
REMARK
If the gearshift lever is operated slowly or is stopped between
gear positions, the central warning lamp may light up and the
alarm buzzer may sound. In this case, there is no failure, but try
to operate the gearshift lever so that the gearshifting is
completed within 2 seconds.
This machine is equipped with a kick-down switch. When the

machine is traveling in 2nd speed, if the button at the tip of the
lift arm control lever is pressed, the transmission will shift down
to 1st speed.
We recommend that you use the kick-down switch when
carrying out digging or loading operations using 1st and 2nd
speed.
For details of the method of use, see "KICKDOWN SWITCH
(PAGE 3-43)".
This machine is equipped with an auto-shift system that

automatically shifts the gear. For details of the method of use,
see "TRANSMISSION SHIFT MODE SELECTOR SWITCH
(PAGE 3-38)" and "AUTOMATIC SHIFT (PAGE 3-51)"
When the machine is traveling at high speed, if the gearshift
lever is operated to a lower speed, such as 4th -> 3rd or 4th ->
2nd, with the accelerator pedal still depressed, the shift down is
not carried out in order to prevent the engine from overrunning.
In this case, the central warning lamp lights up and the alarm
buzzer sounds. At the same time, "E00 OVERRUN
PROTECT" is displayed on the character display.
If the alarm buzzer sounds, release the accelerator pedal
immediately and depress the brake pedal to reduce speed, then
carry out the gearshift operation.
3 - 116
.
OPERATION OPERATION
CHANGING DIRECTION
WARNING
When changing direction between FORWARD and REVERSE, check
that the new direction of travel is safe. There is a blind spot behind the
machine, so be particularly careful when changing direction to travel in
reverse.
Do not switch between FORWARD and REVERSE when traveling at high
speed.
When switching between FORWARD and REVERSE, depress the brake
to reduce the travel speed sufficiently, then change the direction of
travel. (Max.speed for changing direction: 12 km/h (7.5 MPH))
There is no need to stop the machine even when switching

between FORWARD and REVERSE.
Place directional lever (1) in the desired position.
Check that the backup alarm sounds when the directional lever
is set to REVERSE. If the backup alarm does not sound,
contact your Komatsu distributor for repairs.
REMARK
If the directional lever is operated slowly or is stopped midway between the forward and reverse directions, "E01
MAINTENANCE" may be displayed on the character display. In this case, there is no failure, but try to operate
the directional lever so that the change in direction is completed within 2 seconds.
There is a directional selector switch (if equipped) which makes it possible to change the direction of travel by
operating a switch.
If an attempt is made to switch the direction between forward and

reverse while traveling at high speed (when using 3rd or 4th), if the
travel speed and engine speed are in ranges I or II in the chart on
the right, the central warning lamp will light up and the buzzer will
sound.
At the same time, "E00 PARKING BRAKE" is displayed on the
character display.
If the alarm buzzer sounds, depress the brake immediately to
reduce the travel speed, then operate the directional lever to switch
between forward and reverse.
3 - 117
.
OPERATION OPERATION
WHEN USING AUTO-SHIFT

If an attempt is made to switch the direction between forward and reverse when the auto-shift is ON, normally, the
gearshift range will switch F3 -> R2, F4 -> R2, or R3 -> F2, R4 -> F2 to make it possible to move the machine off
quickly.
However, if an attempt is made to shift between forward and reverse when the machine is traveling at high speed
such as shown in ranges I or II in the chart on the right, the central warning lamp will light up and the buzzer will
sound.
At the same time, "E00 PARKING BRAKE" is displayed on the character display.
If the alarm buzzer sounds, depress the brake immediately to reduce the travel speed, then operate the directional
lever to switch between forward and reverse.
In particular, if it is attempted to switch between forward and reverse in range II, the gear range will not shift to 2nd,
but will switch F3 -> R3, F4 -> R4, or R3 -> F3, R4 -> F4. As a result, the reduction in travel speed will be less than
in range I, so care is necessary.
USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE

(if equipped)
WARNING
When the directional selector switch actuation switch is at the ON position, if the directional lever is operated to F or R, 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 at the side of the work equipment control lever.
Priority is given to the operation of the directional lever, so be careful when operating.
When this is done, the central warning lamp lights up and the alarm buzzer sounds.
Set the directional lever and directional selector switch at the side of the work equipment control lever to the N position.
1. Place the directional lever at the N position.
2. Turn on directional selector switch on the right side of switching

panel that enables directional selection.
Position (a): ON
Position (b): OFF
The two pilot lamps light up, i.e. one is the pilot lamp built in the
actuating switch and another is the directional selector pilot
lamp on the machine monitor.
Then the actuating switch enables the forward - reverse
shifting to function.
3 - 118
.
OPERATION OPERATION
If the switch or the lever is in one of the following conditions, set it

to the correct position.
When directional lever is not at N position
If the directional lever is not at the N position, the pilot lamp
flashes, and at the same time, the central warning lamp lights up
and the alarm buzzer sounds.
In this condition, the machine will move forward or in reverse
according to the set position of the directional lever.
Return the directional lever to the N position.
When directional selector switch is at F or R when engine is
started
If the directional selector switch is at F or R, the central warning
lamp lights up and the alarm buzzer sounds.
In this condition, the engine will not start, so set the directional
selector switch to N.
3. Press the directional selector switch on the side of the work
equipment control lever to the desired position.
3 - 119
.
OPERATION OPERATION
STOPPING THE MACHINE

WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
Even if the parking brake switch is turned ON, there is danger until the
parking brake pilot lamp lights up, so keep the brake pedal depressed.
NOTICE
Never use the parking brake switch to brake the machine when traveling except in an emergency. Apply the parking brake only
after the machine has stopped.
1. Release accelerator pedal (1), then depress brake pedal (2) to

stop the machine.
2. Place directional lever (3) in N (neutral) position.
3. Turn parking brake switch (4) to ON to apply the parking brake.
REMARK
When the parking brake is applied, the transmission is
automatically returned to neutral.
3 - 120
.
OPERATION OPERATION
TRANSMISSION CUT-OFF FUNCTION

When the transmission cut-off switch is turned ON, the pilot lamp
lights up and the following transmission cut-off function is actuated.
Position (a): OFF
Position (b): ON
When the left brake pedal is depressed, the brake is actuated, and
in addition, the transmission is shifted to neutral at the pre-selected
brake pedal depression position.
REMARK
The cut-off function is actuated only with the left brake pedal.
When the transmission cut-off switch is at the OFF position, the left brake pedal works in the same way as the
right brake pedal.
For details of adjusting the brake pedal depression position, see "ADJUSTING TRANSMISSION CUT-OFF
POSITION (PAGE 3-122)".
Raise or lower the pre-selected brake pedal depression position to adjust the cut-off to match the type of work
shown below.
When carrying out scooping-up work, lower the brake pedal
depression position for the cut-off (transmission shifted to
neutral). In this setting, the transmission driving force is cut at a
point where there is ample braking force, so this prevents the
machine from slipping down.
When approaching dump trucks during loading operations, raise

the brake pedal depression position for the cut-off (transmission
shifted to neutral). In this setting, the fine control of the braking
immediately before dumping the load can be carried out with the
brake only, so this makes it easy to control and allows the
machine to be brought to a soft stop.
3 - 121
.
OPERATION OPERATION
ADJUSTING TRANSMISSION CUT-OFF POSITION
CAUTION
Apply the parking brake before adjusting the transmission cut-off position.
Adjust the depression position of the left brake pedal used to shift the transmission to neutral at the position to match
the operation.
1. Start the engine with starting switch (1), then set parking brake
switch (2) to the ON position.
2. Set transmission cut-off switch (3) to the ON position.
3. Depress left brake pedal (4) and set it to the desired position to
shift the transmission to neutral.
4. Press transmission cut-off set switch (5), then release it. When
the switch is released, the buzzer will sound with a repeated
short sound, and the cut-off position is set.
Method of canceling cut-off position

5. After the buzzer sounds in Step 4 of the adjustment procedure,
the transmission cut-off switch flashes for 2 seconds. While it
is flashing, press transmission cut-off set switch (5) again and
release it.
6. The buzzer will sound with a long sound and the adjusted
cut-off position is canceled.
STOPPING WHEN TRANSMISSION CUT-OFF IS ON
When the transmission cut-off switch is at the ON position and the left brake pedal is depressed, the transmission
is shifted to neutral at the pre-selected brake pedal depression position.
The transmission is not shifted to neutral when the right brake pedal is operated.
REMARK
When the transmission cut-off switch is OFF, the left brake pedal acts in the same way as the right brake pedal, and
the transmission is not shifted to neutral.
3 - 122
.
OPERATION OPERATION
TURNING
WARNING
Operating the steering wheel suddenly at high speed or operating the steering wheel on steep slopes is dangerous. Do not
operate the steering wheel in such situations.
If the engine stops when the machine is traveling, the emergency steering is actuated. Note that this system is only for steering
in emergencies, so never stop the engine.
It is particularly dangerous if the engine stops when the machine is traveling on slopes, so never let the engine stop when
traveling on slopes.
If the engine stops, stop the machine immediately at a safe place.
When traveling, use steering wheel (1) to turn the machine.

With this machine, the front frame is joined to the rear frame at the
center of the machine by the center pin. The front and rear frames
bend at this point, and the rear wheels follow in the same track as
the front wheels when turning.
Turn the steering wheel lightly to follow the machine as it turns.
NOTICE
When the steering wheel is turned fully, if it reaches the end of its stroke,
do not try to turn it further.
Check that there is a play of 50 to 100 mm (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.
EMERGENCY STEERING
(if equipped)
CAUTION
Never actuate the emergency steering except during emergencies or
when checking the function.
The emergency steering can be used continuously for a maximum of 60
seconds. Operating it continuously for more than 60 seconds may
damage the system.
When using the emergency steering, travel at less than 5 km/h (3.1
MPH).
During emergencies or when stopping the engine to check the

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

operator that the emergency steering system has been actuated.
The emergency steering system is provided to enable the machine to be steered under the following conditions.
The starting switch is at the ON position.
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OPERATION OPERATION
The steering oil pressure is low or there is no pressure.

(When the engine has stopped or there is a failure in the steering oil pressure pump, etc.)
When the starting switch is turned to the ON position, the emergency steering automatically carries out a self check
for 3 seconds. For details, see "EMERGENCY STEERING SELF-CHECK FUNCTION (PAGE 3-124)".
When the emergency steering controller detects lack of oil

pressure in the steering system, steering oil pressure caution lamp
(red) (3) and central warning lamp (4) light up, and the alarm buzzer
sounds intermittently.
When this happens, if the machine is traveling at a speed of more
than 2 km/h (1.2 MPH), the electric pump motor is automatically
actuated and emergency steering pilot lamp (green) (2) lights up.
Steering oil pressure caution lamp (red) (3) lights up to inform the
operator that there is a failure in the steering system.
If steering oil pressure caution lamp (red) (3) lights up, move the machine immediately to a safe place and stop it.
Locate the cause and do not operate the machine until it has been repaired.
REMARK
If any function of the oil pressure system is used when the engine is running at low speed, steering oil pressure
caution lamp (red) (3) may light up for a moment, but if the lamp goes out again soon, there is no problem.
When the emergency steering controller detects that the oil pressure in the steering circuit has been restored, the
actuation of the emergency steering system is stopped.
EMERGENCY STEERING SELF-CHECK FUNCTION

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

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

Lift arm control lever (1) and bucket control lever (2) can be used
to operate the lift arm and bucket as follows.
LIFT ARM CONTROL LEVER
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.
Position (b): HOLD
Position (c): LOWER
Position (d): FLOAT
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.
OPERATION OPERATION
BUCKET CONTROL LEVER

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
Position (c): DUMP
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.
OPERATION OPERATION
WORK POSSIBLE USING WHEEL LOADER

In addition to the following, it is possible to further increase the range of applications by using various attachments.
DIGGING OPERATIONS
For machines equipped with an EPC work equipment lever (option), refer to the section of "SEMI AUTO DIGGING
OPERATIONS (PAGE 6-54)" in the chapter, ATTACHMENT AND OPTION, in this manual.
WARNING
Never carry out digging or scooping operations with the machine articulated. There is danger that the machine may tip over.
When the machine is traveling or the work equipment is raised, the moment that the E.C.S.S. switch is turned ON, the work
equipment will move.
If operations are carried out with the E.C.S.S. switch left at the ON position, the moment that the travel damper is actuated, the
work equipment will move.
NOTICE
If the tires slip, the tire life will be reduced, so do not allow the tires to slip during operation.
LOADING PILED SOIL OR BLASTED ROCK

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

stop the bucket approximately 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. 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
unbalanced.
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.
OPERATION OPERATION
Stock pile
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 prevention of wear of the tires.
5. Check that there is enough material loaded into the bucket,

then operate the bucket control lever to tilt the bucket and load
the bucket fully.
REMARK
If the bucket edge is moved up and down while pushing in the
bucket and digging, the front tires will come off the ground and this
will cause the tires to slip.
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.
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

When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the
machine forward. Always be careful not to load the bucket on one side and cause an unbalanced load.
This operation should be carried out in 1st gear.
CAUTION
Do not set the bucket facing down more than 20 degrees.
1. Set the edge of the bucket facing slightly down.
2. Drive the machine forward and operate the lift arm control lever
forward to cut a thin layer of the surface each time when
excavating the soil.
3. Operate the lift arm control lever slightly up and down to reduce
the resistance when driving the machine forward.
When digging with the bucket, avoid imposing the digging force
on one side of the bucket.
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.
OPERATION OPERATION
LEVELING OPERATIONS
NOTICE
Always operate the machine in reverse when carrying out leveling
operations.
If it is necessary to carry out leveling operations when traveling forward,
do not set the bucket dumping angle to more than 20 degrees.
Turn the E.C.S.S. 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
CAUTION
Never set the bucket to 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

WARNING
When carrying a load, lower the bucket to lower the center of gravity
when traveling.
When the machine is traveling or the work equipment is raised, the
moment that the E.C.S.S. switch is turned ON, the work equipment will
move.
If operations are carried out with the E.C.S.S. switch left at the ON
position, the moment that the travel damper is actuated, the work
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 (PAGE
3-141)".
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.
OPERATION OPERATION
LOADING OPERATIONS
Select the method of operation which will give the minimum amount of turning and travel in order to provide the most
efficient method for the jobsite.
WARNING
Always keep the jobsite flat, and do not operate the steering wheel suddenly or apply the brakes suddenly when the lift arm is
raised with a loaded bucket. This is dangerous.
Never thrust the bucket in when traveling at high speed (when loading soil or crushed rock). This is dangerous.
When the machine is traveling or the work equipment is raised, the moment that the E.C.S.S. switch is turned ON, the work
If operations are carried out with the E.C.S.S. switch left at the ON position, the moment that the travel damper is actuated, the
work equipment will move.
NOTICE
If the tires slip, the tire life will be reduced, so do not allow the tires to slip during operation.
Avoid excessive bucket shaking.
CROSS DRIVE LOADING

Always set the wheel loader facing at a right angle to the stockpile.
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.
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OPERATION OPERATION
V-SHAPE LOADING
Position the dump truck so that the direction of approach of the
wheel loader is approx. 60 deg. 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 DUMP position when piling-up loads.
REMARK
When carrying out scooping-up work, avoid using the transmission cut-off function as far as possible. It will
prevent the machine from moving back.
When using the transmission cut-off function, lower the cut-off position so that cut-off function is actuated, when
the brake pedal is deeply depressed, while ensuring ample braking force.
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OPERATION OPERATION
PRECAUTIONS FOR OPERATION
PERMISSIBLE WATER DEPTH

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

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
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.
BRAKING ON DOWNHILL SLOPE

If the footbrake is used frequently when traveling downhill, the brake will overheat and may be damaged. Place the
gearshift lever at a low speed range and use the braking force of the engine when traveling downhill.
Use the right brake pedal for braking.
If the brakes are used excessively, the axle oil temperature caution lamp may light up and the alarm buzzer may
sound intermittently. For details of the necessary action to take, see "AXLE OIL TEMPERATURE CAUTION LAMP
(PAGE 3-17)" in EXPLANATION OF COMPONENTS.
If the speed range selected by the gearshift lever is not correct, the torque converter oil may overheat. If this
happens, shift down one gear range and reduce the oil temperature.
If the oil temperature does not return to the white range even when the gearshift lever is at 1st, stop the machine,
return the directional lever to the N position, and run the engine at a mid-range speed until the gauge returns to the
white range.
IF ENGINE STOPS
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.
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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 and should be avoided as much as possible. If the machine must be driven for a long distance, take the
following precautions.
Follow the regulations related to this machine, and drive carefully.
Before driving the machine, carry out the checks before starting.
The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface.
Contact your Komatsu distributor or tire dealer for information.
The following is a guide to suitable tire pressures and speeds when traveling on a paved surface with standard
tires. (20.5-25-16PR)
Tire pressure
Front wheel: 0.34 MPa (3.5 kg/cm2, 49.7 PSI)
Rear wheel: 0.34 MPa (3.5 kg/cm2, 49.7 PSI)
Speed:14 km/h (8.7 MPH)
Check the tire pressure before starting, when the tire is cool.
After traveling for one hour, stop the machine for 30 minutes and check the tires and all parts for any abnormality.
Check the oil level and coolant level also.
When stopping the machine in extremely cold areas, do as follows.
To prevent the radiator water temperature from rising suddenly, do not suddenly stop the engine. Gradually cool
the radiator water down before stopping the engine.
Always travel with the bucket empty.
Never put "calcium chloride" or "dry ballast" in the tires when traveling.
PRECAUTIONS REGARDING BRAKE FUNCTION

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

Machine Slope
weight grade Average travel speed Downhill distance limit
(t) (%) limit (km/h (MPH)) (continuous)(km)
16.5 - 18.5 10 40 (24.9) 2

(unloaded) 20 15 (9.3) 0.7
21.6 - 23.6 10 30 (18.6) 1.5
(loaded) 20 12 (7.5) 0.5
If the braking capacity limit is exceeded, a forced cooling system for the brakes is needed, so please consult your
Komatsu distributor.
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OPERATION OPERATION
ADJUSTING WORK EQUIPMENT POSTURE

WARNING
Stop the machine on flat ground and put blocks in front and behind the
wheels.
Apply the parking brake.
Secure the front and rear frames with the frame lock bar.
Always attach the warning tag to the work equipment control lever.
Do not go under the work equipment when the arm is raised.
The boom kickout makes it possible to set the bucket so that it

automatically stops at the desired lifting height (lift arm higher than
horizontal) and the bucket positioner makes it possible to set the
bucket so that it automatically stops at the desired digging angle.
The setting can be adjusted to match the working conditions.
For machines equipped with an EPC work equipment lever (if

equipped), refer to the section of "METHOD OF REMOTE
POSITIONER (PAGE 6-56)" in the chapter, ATTACHMENT AND
OPTION, in this manual.
ADJUSTING BOOM KICKOUT

1. Raise the bucket to the desired position, return the lift arm
control lever to the HOLD position, set the work equipment lock
lever to the LOCK position, then stop the engine.
2. Loosen two bolts (1), and adjust plate (2) so that the bottom
edge is in line with the center of the sensing surface of
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 surface of
proximity switch (3). Then tighten the nuts to hold in position.
Tightening torque: 17.2 ± 2.5 Nm {1.75 ± 0.25 kgm, 12.7 ±
1.8 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.
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OPERATION OPERATION
ADJUSTING BUCKET POSITIONER

1. Lower the bucket to the ground, set it to the desired digging
angle, return the bucket control lever to the HOLD position, set
the work equipment lock lever to the LOCK position, then stop
the engine.
2. Loosen 2 bolts (1), adjust the position of mounting bracket (4)
of the proximity switch so that the rear tip of bar (2) is in line with
the center of the sensing surface of proximity switch (3), then
tighten bolts to hold the bracket in position.
3. Loosen 2 bolts (5), adjust so that the clearance between bar (2)
and support (6) is 0.5 to 2 mm (0.020 to 0.079 in), then tighten
bolts (5) to hold in position.
4. Loosen 2 nuts (7), adjust so that the clearance between bar (2) and the sensing surface of proximity switch (3)
is 3 to 5 mm (0.118 to 0.197 in), then tighten the nuts to hold in position.
5. After adjusting, start the engine and raise the lift arm. Operate the bucket control lever to DUMP position, then
operate it to TILT BACK position and check that the lever is automatically returned to HOLD position when the
bucket reaches the desired digging angle.
BUCKET LEVEL INDICATOR

(A) and (B) at the top rear of the bucket are the level indicators.
They check the bucket angle during operations.
(A): Parallel with cutting edge
(B): 90 deg. to cutting edge
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OPERATION OPERATION
PARKING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
Do not park the machine on slopes.
If the machine has to be parked on a slope, set it facing directly down the
slope, then dig the bucket into the ground and put blocks under the tires
to prevent the machine from moving.
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 work
equipment lock lever securely to the LOCK position.
Even if the parking brake switch is turned ON, there is danger until the
parking brake pilot lamp lights up, so keep the brake pedal depressed.
NOTICE
Never use the parking brake switch to brake the machine when traveling
except in an emergency. Apply the parking brake only after the machine
has stopped.
1. Release accelerator pedal (1), then depress brake pedal (2) to

stop the machine.
2. Place directional lever (3) in N (neutral) position.
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.
OPERATION OPERATION
3. Set parking brake switch (4) to the ON position to apply the

parking brake.
NOTICE
When the parking brake is applied, the transmission is automatically
returned to neutral.
4. Operate lift arm control lever (5) to lower the bucket to the
ground.
5. Check that the lift arm control lever (5) and bucket control lever
(6) is at the HOLD position, then set the work equipment lock
lever (7) to the LOCK position.
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.
OPERATION OPERATION
CHECKS AFTER COMPLETION OF OPERATION
BEFORE STOPPING ENGINE

Check the engine water temperature, engine oil pressure, torque converter oil temperature, and fuel level with the
machine monitor.
If the engine has overheated, do not stop it suddenly. Run the engine at a midrange speed to allow the engine to
cool down before stopping it.
AFTER STOPPING ENGINE

1. Walk around the machine and check the work equipment, bodywork, 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.
LOCKING
Always lock the following parts.
(1) Fuel tank filler cap
(2) Engine side panel (2 points)
(3) Cab door (2 points)
REMARK
The starting switch key is used also for locks (1), (2), and (3).
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.
OPERATION OPERATION
HANDLING THE TIRES
PRECAUTIONS WHEN HANDLING TIRES

CAUTION
If a tire has reached any of the following service limits, there is danger that
the tire may burst or cause an accident, so to ensure safety, replace it with
a new tire.
Service limits for wear
When the remaining depth of the grooves on construction equipment
tires (at a point approximately 1/4 of the tread width) is 15% of the
groove depth on a new tire.
When the tire shows marked uneven wear, stepped wear or other
abnormal wear, or when the cord layer is exposed.
Service limits for damage
When there is external damage extending to the cord or when the cord
is broken
When the cord is cut or there is dragging
When the tire is peeling (there is separation)
When the bead is damaged
For tubeless tires, when there is air leakage or improper repair
Consult your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due
care.
TIRE PRESSURE
Measure the tire pressure before starting operations, when the tires are cool.
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): approximately 15 to 25 %
When digging (rear wheels off ground): approximately 25 to 35 %
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.
OPERATION OPERATION
When checking the tire inflation pressure, check also for small scratches or peeling of the tire, for nails or pieces of
metal which may cause punctures, and for any abnormal wear.
Clearing fallen stones and rocks from the operating area and maintaining the surface will extend the tire life and give
improved economy.
For operations on normal road surfaces, rock digging operations: High end of range in air pressure chart
Stockpile operations on soft ground: Average pressure in air pressure chart
Operations on sand (operations not using much digging force): Low end of range in air pressure chart
If the deflection of the tire is excessive, raise the inflation pressure within the limits given in the table to give a suitable
deflection (see deflection ratio).
Inflation pressure [MPa (kgf/cm2, PSI)]

H
Tire size Soft ground
Free height Normal road When shipped
(Pattern) (sandy ground)
(mm) from factory
Stockpile Stockpile Digging
20.5-25-16PR
(Standard)
387 (BS)
20.5-25-20PR
383 (TOYO)
(L3: Rock) Front tire: 0.34
0.26 - 0.37 0.27 - 0.44 0.27 - 0.44
(if equipped) (3.5, 49.7)
(2.6 - 3.8, (2.8 - 4.5, (2.8 - 4.5,
20.5-25-16PR Rear tire: 0.34
36.9 - 54.0) 39.8 - 63.9) 39.8 - 63.9)
386 (BS)
20.5-25-20PR
385 (TOYO)
(L2: Traction)
(if equipped)
23.5-25-16PR
424 (BS)
(L3: Rock) Front tire: 0.30
423 (TOYO) 0.24 - 0.35 0.26 - 0.35 0.26 - 0.35
(2.4 - 3.6, (2.6 - 3.6, (2.6 - 3.6,
23.5-25-16PR Rear tire: 0.30
434 (BS) 34.1 - 51.1) 36.9 - 51.1) 36.9 - 51.1)
(L2: Traction) (3.1, 44.0)
422 (TOYO)
(if equipped)
Stockpile operations mean the loading of sand and other loose

materials.
PRECAUTIONS FOR USING LOAD AND CARRY METHOD

When traveling continuously with load and carry operations, choose the correct tires to match the operating
conditions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged, so
contact your Komatsu distributor or tire dealer when selecting tires.
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TRANSPORTATION OPERATION
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION PROCEDURE
When transporting the machine, choose the optimum transportation method in reference to the weight and
dimensions shown in "SPECIFICATIONS (PAGE 5-2)". Note that machine specifications (weight and dimensions)
vary depending on the kind of tire and bucket.
LOADING, UNLOADING WORK WITH TRAILERS

WARNING
When loading or unloading the machine, run the engine at low speed, travel at low speed, and operate slowly.
When loading or unloading the machine, stop the trailer on firm level ground.
In addition, keep well away from the road shoulder.
Use ramps of ample width, length, thickness, and strength, and install them securely at an angle of less than 15 deg.
When using an embankment, compact the fill soil thoroughly and make sure that the slope face does not collapse.
Remove the mud stuck to the undercarriage to prevent the machine from slipping to the side on the ramps.
In addition, remove any water, snow, ice, grease, or oil from the ramps.
Never change direction on the ramps. There is danger that the machine may tip over.
If it is necessary to change direction, return to the ground surface or the trailer platform, correct the direction, and start again.
The position of the center of gravity of the machine will change suddenly at the connection of the ramp and trailer, and there
is danger of the machine losing its balance. Always drive slowly over this point.
When loading or unloading, always use ramps or a platform. Proceed as follows.
LOADING
1. Load 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 (1)
under the tires to hold the trailer in position.
Set the distance (3) between ramps (2) to match the distance
between the left and right tires, and make angle (4) of the
ramps a maximum of 15 deg.
If ramps (2) sag appreciably under the weight of the machine,
put wooden block (5) under the ramps to support them.
3. Determine the direction of the ramp, then slowly load the
machine.
4. Load the machine correctly in the specified position on the
trailer.
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.
OPERATION TRANSPORTATION
SECURING MACHINE
Load the machine onto a trailer as follows:
1. Lower the work equipment slowly.
2. Check that the work equipment control lever is at the HOLD
position, then set the work equipment lock lever to the LOCK
position.
3. Set the parking brake switch to ON position (A) to apply the

parking brake securely.
4. Turn the starting switch to the OFF position and stop the
engine.
Remove the key from the starting switch.
5. Lock the front and rear frame with the frame lock bar.
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.
6. Put blocks in front and behind the wheels, and secure the machine with chains or wire rope to prevent the
machine from moving during transportation.
In particular, attach the machine securely to prevent it from slipping sideways.
Fastening positions
7. Stow the antenna away.
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.
UNLOADING
1. 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 (1)
under the tires to hold the trailer in position.
Set the distance (3) between ramps (2) to match the distance
between the left and right tires, and make angle (4) of the
ramps a maximum of 15 deg.
If ramps (2) sag appreciably under the weight of the machine,
put wooden block (5) under the ramps to support them.
3. Remove the chains and wire ropes fastening the machine.

4. Set the frame lock bar to FREE position.
5. Start the engine.
Warm the engine up fully.

position, then set the work equipment lock lever to the FREE
position.
7. Depress the right brake pedal, then turn the parking brake
switch OFF (release) to release the parking brake.
Keep the right brake pedal depressed.
8. Determine the direction of the ramps, then drive the machine
slowly down the ramps to unload the machine.
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LIFTING MACHINE
WARNING
The person using the crane to carry out lifting operations must be a qualified crane operator.
Never carry out lifting operations if any person is on the machine being lifted.
Always use a wire rope that has ample strength for the weight of the machine being lifted.
Keep the machine horizontal when lifting it.
When carrying out lifting operations, do as follows to prevent the machine from moving unexpectedly.
Set the parking brake switch to the ON position.
Set the work equipment lock lever to the LOCK position.
Set the frame lock bar to the LOCK position.
Never enter the area under or around a raised machine.
There is danger of the machine losing its balance.
Use the procedure below to set the machine in the proper posture and use the lifting equipment when lifting the machine.
NOTICE
This method of lifting applies to the standard specification machine.
The method of lifting differs according to the attachments and options installed.
For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor.
For weight, see "SPECIFICATIONS (PAGE 5-2)".
LIFTING PROCEDURE
Lifting position
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.
The machine can be lifted only if it has hook mark labels.

When lifting the machine, stop the machine on level ground and do as follows.
1. Start the engine, set the machine horizontal, and set the work
equipment in the travel posture (see "MOVING THE
MACHINE (PAGE 3-113)").
(A): 40 to 50 cm (16 to 20 in)

position, then set the work equipment lock lever to the LOCK
position (L).
3. Stop the engine, check that the area around the operator's
compartment is safe, then lock with the frame lock bar so that
the front frame and rear frame do not articulate.
4. Use wire ropes and slings that match the weight of the machine, and wind the wire rope and fix it to the lifting
points as shown in the figure.
NOTICE
Use protectors, etc. so that the wire ropes will not be broken at sharp edges or narrow places.
Use threaders and bars having sufficient width so that the slings and wire ropes will not touch the machine.
For machines equipped with a rear full fender, remove the rear full fender before carrying out the operation.
5. After setting the wire ropes, lift up the machine and stop at 100 to 200 mm (3.9 to 7.9 in) above the ground, and
check that the wire ropes are not slack and the machine is level, then lift up slowly.
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COLD WEATHER OPERATION OPERATION
COLD WEATHER OPERATION

PRECAUTIONS FOR LOW TEMPERATURE
If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.
FUEL AND LUBRICANTS

Change to fuel and oil with low viscosity for all components.
For details of the specified viscosity, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-9)".
COOLANT
WARNING
Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin, wash
it off with large amounts of fresh water and see a doctor at once.
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator,
contact your Komatsu distributor or request a specialist company to perform the operation. Antifreeze is toxic. Do not let it
flow into drainage ditches or spray it onto the ground surface.
Antifreeze is flammable. Do not bring any open flame close. Do not smoke when handling antifreeze.
NOTICE
Use Komatsu Supercoolant wherever available, or use permanent type antifreeze coolant.
Never use methanol, ethanol, or propanol-based antifreeze.
Do not use any water leakage prevention agent, either alone, or in combination with antifreeze.
Do not mix one brand of antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant, see "CLEAN INSIDE OF COOLING SYSTEM
(PAGE 4-21)".
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OPERATION COLD WEATHER OPERATION
BATTERY
WARNING
The battery generates flammable gas. Do not bring open flame near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger
that the battery may explode.
Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
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%. Insulate it against cold
temperature to ensure the machine can be started easily the next morning.
REMARK
Measure the specific gravity and calculate the charging rate from the following conversion table.
Electrolyte
Temperature 20°C 0°C -10°C -20°C
Charging (68°F) (32°F) (14°F) (-4°F)
Rate (%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine, store
the battery in a warm place, and install it again the next morning.
If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add water after the
day's work to prevent diluted electrolyte in the battery from freezing during the night.
PRECAUTIONS AFTER COMPLETION OF WORK

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the
following morning, observe the following precautions.
Remove all the mud and water from the machine. In particular, wipe the hydraulic cylinder rods clean to prevent
damage to the seal caused by mud, dirt, or drops of water on the rod from getting inside the seal.
Park the machine on hard, dry ground.
If this is impossible, park the machine on boards.
The boards prevent the tracks from freezing to the ground, and allow the machine to be moved the next morning.
Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
Fill the fuel tank to capacity. This minimizes moisture condensation in the tank when the temperature drops.
AFTER COLD WEATHER

When the season changes and the weather becomes warmer, do as follows.
Replace all fuel and oil with fuel and oil of the specified viscosity. For details, see "RECOMMENDED FUEL,
COOLANT, AND LUBRICANT (PAGE 4-9)".
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COLD WEATHER OPERATION OPERATION
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER
WARNING
If the steering wheel is operated and stopped while the oil temperature is
low, there may be a time lag before the machine stops turning.
In this case, use the frame lock bar to ensure safety, and perform the
warm-up operation in a wide place.
Do not relieve 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 operation
for approximately 10 minutes to warm up the oil.)
NOTICE
Turn the steering wheel a little and stop in that position. Confirm that the machine turns by an angle equivalent to the amount that
the steering wheel is turned.
RECOMMENDED OIL
Select the oil from the table below according to the ambient temperature.
If SAE5W-20CD is used in the cold season, replace it with TO10 oil when the cold season finishes.
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OPERATION LONG-TERM STORAGE
LONG-TERM STORAGE
BEFORE STORAGE
When keeping in long-term storage (more than 1 month), store as follows.
Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select level
ground and cover the machine with a sheet.
Completely fill the fuel tank. This prevents moisture from collecting.
Lubricate and change the oil before storage.
Coat the exposed portion of the hydraulic cylinder piston rod with grease.
Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately.
Set the work equipment lock lever to LOCK position to prevent the machine from moving.
To prevent corrosion, be sure to fill the cooling system with Supercoolant (AF-NAC) or permanent type antifreeze
(density between 30% and 68%).
DURING STORAGE
WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors and windows to improve
ventilation and prevent gas poisoning.
During storage, perform the rust prevention operation and move the machine for a short distance once a
month so that a new film of oil will coat moving parts. At the same time, charge the battery as well.
When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a month to
lubricate all parts of the air conditioner compressor. Always run the engine at Low idle (MIN) when doing this.
In addition, check the refrigerant level twice a year.
PROCEDURE FOR RUST PREVENTION OPERATION
1. Check the safety around the machine, and check for any problem on the machine (leakage of coolant and oil).
2. Check the oil level and coolant level on each part.
Check them in the following order.
(1) Sub-tank coolant level
(2) Engine oil level
(3) Hydraulic oil level
3. Start the engine and run it at low idle for 5 minutes.
4. Check for abnormality on the machine monitor and machine.
If any abnormality (noise, vibration, etc.) is found, stop the engine immediately, and ask your Komatsu distributor
for inspection and maintenance.
5. Check the oil level in the transfer or transmission.
6. Depress the accelerator pedal to the midpoint in order to run the engine at a medium speed, and fully extend and
fully retract each hydraulic cylinder repeatedly 5 times.
7. To lubricate the axle, drive the machine forward and reverse (forward and reverse travel of 10 m {32 ft 10 in} for
3 times).
8. Set the machine in the parking posture and stop the engine to park the machine.
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LONG-TERM STORAGE OPERATION
AFTER STORAGE
NOTICE
If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor
before using it.
When using the machine after long-term storage, do as follows before using it.
Wipe off the grease from the hydraulic cylinder rods.
Add oil and grease at all lubrication points.
When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and after
starting the engine. If there is water in the oil, change all the oil.
Check that there is no rust on the engine pulley and no abnormality in the belt.
If there is excessive rust on the belt contact surface of the pulley, remove it with a wire brush.
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OPERATION TROUBLESHOOTING
TROUBLESHOOTING
WHEN MACHINE RUNS OUT OF FUEL
In case that the machine has run out of fuel, start the engine again only after refilling fuel, filling the water separator
and fuel filter cartridge with clean fuel and bleeding air from the fuel system.
Always watch the fuel level and be careful not to run out of fuel.
If the engine has stopped because of lack of fuel, it is necessary to use the priming pump to bleed the air completely
from the fuel circuit.
PROCEDURE FOR BLEEDING AIR
CAUTION
Be careful when unscrewing the air bleeding plug on the fuel filter head. Oil may spurt out due to the residual pressure inside the
tank.
If clean fuel is not available, go on to Step 3.

1. Remove water separator (1), fill the inside of the strainer with
clean fuel, taking care not to let dirt or dust get in, then install
it again.
2. Remove fuel filter cartridge (2), fill the inside of the filter with
clean fuel, taking care not to let dirt or dust get in, then install
it again.
Add fuel from small hole (A) (dirty side) at eight places. Do not
add fuel from hole (B) (clean side) at the center.
3. Loosen air bleed plug (3) at the fuel filter head.
4. Bleed air with priming pump (4) and check that air bubbles
come out of air bleeding plug (3), followed by fuel.
5. Tighten air bleed plug (3).
Tightening torque: 7.8 to 9.8 Nm (0.8 to 1 kgm , 5.8 to 7.2 lbft)
6. Turn the key in the starting switch to START position and start the engine.
When doing this, do not crank the starting motor continuously for more than 20 seconds. If the engine does not
start, wait for at least 2 minutes, then try again. Perform this operation a maximum of 4 times.
7. If the engine does not start, repeat the operation from Step 3.
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TROUBLESHOOTING OPERATION
METHOD OF TOWING MACHINE

WARNING
Serious injury or death could result if there is any mistake in the selection
of wire rope or method of towing a disabled machine.
Always be sure to check carefully that the capacity of the wire rope used
for towing is ample for the weight of the towed machine.
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.
Always wear leather gloves when handling wire rope.
Never tow a machine on a slope.
During the towing operation, never stand between the towing machine
and the machine being towed.
Move the machine slowly and be sure not to apply any sudden load on
the wire rope.
If there is a failure in the brake line, the brakes cannot be used, so be
extremely careful when towing.
NOTICE
Only tow the machine for a short distances, such as to a place for inspection or maintenance.
The machine must not be towed for long distances.
For details of the permissible towing load for this machine, see Section "SPECIFICATIONS (PAGE 5-2)".
For details of the procedure for towing a machine when it has broken down, contact your Komatsu distributor.
This machine must not be towed except in emergencies. When towing the machine, take the following precautions.
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.
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.
If it is impossible to operate the steering and brakes of the machine being towed, do not let anyone ride on the
machine.
Keep the angle of the towrope as small as possible. Keep the angle between the centerlines of the 2 machines
to within 30 deg.
The towing machine should normally be of the same class as the machine being towed. Check that the towing
machine and towed machine both have ample braking power and that the towing machine has ample rimpull to
control both machines on the slopes or on the tow road.
When towing a machine downhill, it may be necessary to connect another machine to the rear of the machine
being towed in order to provide ample rimpull and braking power. This makes it possible to prevent the machine
from losing control.
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 rim pull.
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Connect a wire rope to the part indicated with the arrow in the
figure at right.
WHEN ENGINE CAN BE USED

If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the
machine out of mud or to move it for a short distance to the edge of the road.
The operator should sit on the machine being towed and operate the steering in the direction that the machine
is towed.
WHEN ENGINE CANNOT BE USED

When towing a machine with the engine stopped, use the following procedure.
1. The transmission oil does not lubricate the system, so remove the front and rear drive shafts. If necessary, block
the tires to prevent the machine from moving.
2. The steering cannot be operated, so remove the steering cylinder.
Even if the brakes are in good condition, the brakes can only be used a limited number of times. There is no
change in the operating force for the brake pedal, but the braking force is reduced each time the pedal is
depressed.
3. Connect the towing equipment securely. When carrying out towing operations, use 2 machines of at least the
same class as the machine being towed. Connect 1 machine each to the front and rear of the machine being
towed, then remove the blocks from the tires and tow the machine.
4. Parking brake
The parking brake cannont be turned OFF. To release the parking brake, do as follows.
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RELEASING PARKING BRAKE

WARNING
When releasing the parking brake, stop the machine on level ground and check that the surrounding area is safe. If it is
necessary to release the brake on a slope in an emergency, block the tires before starting the operation.
If the parking brake is released, the brake cannot be used, so check the safety carefully when moving the machine.
If the engine will not run for some reason, use the following methods to release the parking brake and tow the
machine.
METHOD OF RELEASING BRAKE BY USING EMERGENCY PARKING BRAKE CANCEL SWITCH
CAUTION
When the parking brake switch is at the OFF position and the emergency parking brake release valve is opened, the parking brake
is released immediately.
In this condition, even if you feel danger and try to stop the machine, the parking brake will not be applied immediately even if you
close the emergency parking brake release valve.
If the pressure in the brake accumulator is high, do as follows.

1. Turn the starting switch to OFF position (A).
2. Turn locknut (1) of the release valve counterclockwise, then

turn grip (2) counterclockwise to open the release valve.
REMARK
The relief valve is located on the left front portion inside the rear
frame and secured to the accumulator mounting bracket.
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.
3. Turn starting switch to ON position (B).
4. Move the parking brake switch to the ON (a) position

(actuated), then move it to the OFF (b) position (released).
The parking brake is released.
5. To restore the function of the parking brake, turn grip (2) of the
release valve clockwise to close the release valve, then turn
locknut (1) clockwise to lock it.
Tightening torque
Grip (2): 25 ± 5 Nm (2.5 ± 0.5 kgm , 18.1 ± 3.6 lbft)
Locknut (1): 20 ± 5 Nm (2.0 ± 0.5 kgm , 14.5 ± 3.6 lbft)
6. Move the parking brake switch to the ON (a) position. The
parking brake is applied.
To release the parking brake again, repeat the procedure in
Steps 1 to 4.
REMARK
If the brake accumulator pressure is low, the parking brake warning lamp may not go out, or the alarm buzzer may
sound continuously. If this happens, go to the following section "METHOD OF RELEASING MECHANICALLY" and
release the brake.
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METHOD OF RELEASING MECHANICALLY

1. Remove plugs (1) and (2) at the front of the transmission case.
2. Of the bolts installing the parking brake chamber, 4 bolts (3)
have a high (3 mm (0.118 in)) mounting seat. Remove 2 of
bolts (3).
3. Screw bolts (3) into the holes from which plugs (1) and (2) were
removed and tighten uniformly until they stop.
4. This releases the parking brake.
(A) Plug mounting hole

(Taper mounting hole)
(B) Therad hole M12 for releasing
EMERGENCY TRAVEL OPERATION

The normal gear shifting operation is carried out by electric signals. If there should be a failure in the electrical
system and the machine does not move, contact your Komatsu distributor to have the machine moved.
NOTICE
Always request your Komatsu distributor to carry out the emergency travel operation.
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IF BATTERY IS DISCHARGED
WARNING
It is dangerous to charge a battery installed on a machine. Make sure
that it is removed before charging.
When checking or handling the battery, stop the engine and turn the
starting switch key to OFF position.
The battery generates hydrogen gas, so there is a hazard of explosion.
Do not bring lighted cigarettes near the battery, or do nothing that will
cause sparks.
Battery electrolyte is dilute sulfuric 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.
When handling batteries, always wear protective eyeglasses and rubber
gloves.
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.
If the terminals are loose, there is danger that the defective contact may
generate sparks that will cause an explosion.
When installing the terminal, securely install it.
When removing or installing the terminals, check which is the positive
(+) terminal and which is the negative (-) terminal.
REMOVAL AND INSTALLATION OF BATTERY

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
nuts of the terminal and remove the wires from the battery.
2. After installing the battery, fix it with the battery hold down.
Tightening torque: 2 to 2.9 Nm
{0.2 to 0.3 kgm, 1.4 to 2.2 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 Nm
{0.6 to 1.0 kgm, 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 left side of the
machine.
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PRECAUTIONS FOR CHARGING BATTERY

When charging the battery, if the battery is not handled correctly,
there is danger that the battery may explode. Always follow the
instructions in "BATTERY (PAGE 3-149)" and the instruction
manual accompanying the charger, and do as follows.
Do not use or charge the battery if the battery electrolyte level is
below LOWER LEVEL line. This may cause an explosion.
Check the battery electrolyte level periodically and add distilled
water to bring the electrolyte level to UPPER LEVEL line.
Set the voltage of the charger to match the voltage of the battery
to be charged. If the correct voltage is not selected, the charger
may overheat and cause an explosion.
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 attach the clips
securely.
Set the charging current to 1/10 of the value of the rated battery capacity; when performing rapid charging, set
it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire and
explode.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a danger that this will ignite the battery electrolyte and cause the battery to explode.
STARTING ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows.
PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE
WARNING
When connecting the cables, never contact the positive (+) and negative
(-) terminals.
When starting the engine with a booster cable, wear protective
eyeglasses and rubber gloves.
Be careful not to let the normal machine and problem machine contact
each other. This prevents sparks from generating near the battery which
could ignite the hydrogen gas given off by the battery.
Make sure that there is no mistake in the booster cable connections.
The final connection is to the engine block of the problem machine, but
sparks will be generated when this is done, so connect to a place as far
as possible from the battery.
When disconnecting the booster cable, take care not to bring the clips
in contact with each other or with the machine.
NOTICE
Use a booster cable and clip of a thickness to match the size of the battery.
The battery on the normal machine must be the same capacity as the battery on the failed machine.
Check that there is no breakage or corrosion of the cable or clip.
Connect the clip securely.
Check that the work equipment lock levers on both the machines are at LOCK position and that the parking brake is applied.
Check that all levers are at Neutral position.
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CONNECTING THE BOOSTER CABLE

Keep the starting switch of the normal machine and failed machine in OFF position.
Connect the booster cable as follows, in the order of the numbers marked in the figure.
1. Connect 1 clip of booster cable (A) to the positive (+) terminal
of the problem machine.
2. Connect the other clip of booster cable (A) to the positive (+)
terminal of the normal machine.
3. Connect 1 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.
STARTING ENGINE
WARNING
Always check that the work equipment lock lever is set to LOCK position, regardless of whether the machine is working normally
or has failed. Check also that all the control levers are in HOLD or NEUTRAL position.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start engine of the normal machine and run it at High idle (MAX).
3. Turn the starting switch of the problem machine to 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 connected.
1. Remove 1 clip of booster cable (B) from the engine block of the
problem machine.
2. Remove the other clip of booster cable (B) from the negative (-)
3. Remove 1 clip of booster cable (A) from the positive (+)
4. Remove the other clip of booster cable (A) from the positive (+)
terminal of the problem machine.
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OTHER TROUBLE
ELECTRICAL SYSTEM
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Problem Main causes Remedy

Lamp does not glow brightly even Defective wiring ( Check, repair loose terminals,
when the engine runs at high disconnections)
speed Defective adjustment of belt Adjust alternator belt tension For
Lamp flickers while engine is tension details, see EVERY 250 HOURS
running SERVICE
Even when the engine is rotating, Defective alternator ( Replace)

the battery charge circuit caution Defective wiring ( Check, repair)
lamp does not go out Defective adjustment of alternator Adjust alternator belt tension For
belt tension details, see EVERY 250 HOURS
SERVICE
Abnormal noise is generated from Defective alternator ( Replace)

alternator
Starting motor does not turn when Defective wiring ( Check, repair)
starting switch is turned to ON Insufficient battery charge Charge
Pinion of starting motor keeps Insufficient battery charge Charge

going in and out
Starting motor turns engine Insufficient battery charge Charge
sluggishly Defective starting motor ( Replace)
Starting motor disengages before Defective wiring ( Check, repair)
engine starts Insufficient battery charge Charge
Preheating pilot lamp does not Defective wiring ( Check, repair)

light up Defective glow relay, glow ( Replace)
controller, water temperature
sensor
Defective preheating pilot lamp ( Replace)
Even when engine is stopped, Defective wiring ( Check, repair)

battery charge circuit caution Defective monitor ( Replace)
lamp does not light up (starting
switch at ON position)
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CHASSIS

Transmission
Engine is running but machine Parking brake is applied Release parking brake
does not move Directional lever is not shifted Shift lever properly
properly
Lack of oil in transmission case Add oil to specified level. See
WHEN REQUIRED
Even when engine is run at full Lack of oil in transmission case Add oil to specified level. See
throttle, machine only move WHEN REQUIRED
slowly and lacks power Screen is clogged ( Disassemble, clean)
Oil overheats Too much oil or too little oil in Add or drain oil to specified level.
transmission case See WHEN REQUIRED
Machine is not traveling in correct Place in correct speed range
speed range
Torque converter is stalled for Reduce stall time
long periods
Engine is overheating ( Check engine)
Noise generated Lack of oil in transmission case Add oil to specified level. See
WHEN REQUIRED
Axle
Noise generated Lack of oil Add oil to specified level.
See WHEN REQUIRED
Improper oil used (for machines Change to specified oil
with limited-slip differential)
Brake
Brake is not applied when pedal is Disc has reached wear limit ( Replace disc)
depressed Lack of oil in hydraulic tank Add oil to specified level. See
EVERY 100 HOURS
Air in brake line Bleed air
Vent hole of brake valve is clogged Clean

Brake drags or remains applied
Brakes squeal Disc is worn ( Replace disc)

Large amount of water in axle oil Change axle oil
Deteriorated axle oil due to Change axle oil
overuse of brake
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.

Steering
Steering wheel is heavy Lack of oil in hydraulic tank Add oil to specified level. See
EVERY 100 HOURS SERVICE
Steering wheel is loose Play in steering cylinder pin ( Grease bearing or replace pin
and bushing where there is
play)
Lack of oil in hydraulic tank Add oil to specified level. See
Parking brake
Braking effect is poor Disc is worn ( Replace disc)
Brake drags or remains applied Lack of oil in transmission case Add oil to specified level. See
WHEN REQUIRED
Screen is clogged ( Disassemble and clean)
Hydraulic system
Lack of lifting power for bucket Lack of oil in hydraulic tank Add oil to specified level. See
Bucket takes time to rise Clogged hydraulic tank filter Replace filter. See EVERY 2000
HOURS SERVICE
Excessive bubbles in oil Low quality oil being used Replace with good quality oil
Lack of oil in hydraulic tank Add oil to specified level. See
Air in oil line Bleed air. See EVERY 2000
HOURS SERVICE
Hydraulic pressure is low Lack of oil in hydraulic tank Add oil to specified level. See
causes pump to suck in air EVERY 100 HOURS SERVICE
Then bleed air. See EVERY 2000
HOURS SERVICE
Movement of cylinder is irregular Lack of oil in hydraulic tank Add oil to specified level. See
3 - 164
.
ENGINE

Engine oil pressure caution lamp Low engine oil pan oil level Add oil to specified level, see
lights up (sucking in air) CHECK BEFORE STARTING
Clogged oil filter cartridge Replace cartridge, see EVERY
500 HOURS SERVICE
Defective tightening of oil pipe ( Check, repair)
joint, oil leakage from damaged
part
Defective monitor ( Replace)
Steam is emitted from top part of Low cooling water level, water Check, add cooling water, repair,
radiator (pressure valve) leakage see WHEN REQUIRED
Defective fan pump or motor ( Check, repair)
Engine water temperature gauge Dirt or scale accumulated in Change cooling water, clean
is in red range cooling system inside of cooling system, see
Engine cooling water temperature WHEN REQUIRED
caution lamp lights up Clogged radiator fin or damaged Clean or repair, see WHEN
fin REQUIRED
Defective thermostat ( Replace thermostat)
Defective thermostat seal ( Replace thermostat seal)
Loose radiator filler cap (high Tighten cap or replace packing
altitude operation)
Defective monitor ( Replace)
Engine water temperature gauge Defective thermostat ( Replace thermostat)

is in white range Defective monitor ( Replace)
Engine does not start when Lack of fuel Add fuel, see CHECK BEFORE
starting motor is turned STARTING
Air in fuel system Repair place where air is sucked in
Fuel filter with fuel. See EVERY
No fuel in fuel filter 500 HOURS SERVICE
( Replace pump or injector)
Defective injection pump or injector
Starting motor cranks engine too See ELECTRICAL SYSTEM
slowly
Starting motor does not turn See ELECTRICAL SYSTEM
Preheating pilot lamp does not See ELECTRICAL SYSTEM
light up
Defective valve clearance ( Adjust valve clearance)
(Defective compression)
Exhaust gas is white or blue Too much oil in oil pan Add oil to specified level, see
Improper fuel Change to specified fuel
3 - 165
.

Exhaust gas occasionally turns Clogged air cleaner element Clean or replace, see WHEN
black REQUIRED
Defective injector ( Replace injector)
Defective compression ( See defective compression
above)
Defective turbocharger ( Clean or replace turbocharger)
Combustion noise occasionally Defective nozzle ( Replace nozzle)

makes breathing sound
Abnormal noise generated Low grade fuel being used Change to specified fuel
(combustion 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 - 166
.
4-1
.
GUIDES TO MAINTENANCE MAINTENANCE
GUIDES TO MAINTENANCE
Do not perform 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
performed.
KOMATSU GENUINE REPLACEMENT PARTS:

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

For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity
according to the ambient temperature.
ALWAYS USE CLEAN WASHER FLUID:

Use automobile window washer fluid, and be careful not to let any dirt get into it.
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 perform suitable
action.
FUEL STRAINER:
Do not remove the strainer from the filler port when adding fuel.
WELDING INSTRUCTIONS:
Turn off the engine starting switch.
Do not apply more than 200 V continuously.
Connect grounding cable within 1 m (3 ft 3 in) of the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may malfunction.
If a seal or bearing happens to come between the part being welded and grounding point, change the grounding
point to avoid such parts.
Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
DO NOT DROP THINGS INSIDE MACHINE:

When opening inspection windows or the oil filler port of the tank to perform inspection, be careful not to drop nuts,
bolts, or tools inside the machine.
If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine, and will
lead to failure. If you drop anything inside the machine, always remove it immediately.
Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
DUSTY WORKSITES:
When working at dusty worksites, do as follows:
Clean the radiator core frequently to avoid clogging.
Clean and replace the fuel filter frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
4-2
.
MAINTENANCE GUIDES TO MAINTENANCE
When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting
into the oil.
AVOID MIXING OIL:

If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade
of oil. Never mix different brand or grade of oil.
LOCKING INSPECTION COVERS:

Lock inspection cover securely into position with the lock bar. If inspection or maintenance is performed with
inspection cover not locked in position, there is a danger that it may be suddenly blow shut by the wind and cause
injury to the worker.
BLEED 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 from the circuit. See "CHANGE OIL IN HYDRAULIC TANK, REPLACE
HYDRAULIC FILTER ELEMENT (PAGE 4-56)".
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES:

When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace with new parts.
When doing this, be careful not to forget to assemble the O-rings and gaskets.
When installing the hoses, do not twist them or bend them sharply. If they are installed so, their service life will
be shortened extremely and they may be damaged.
CHECKS AFTER INSPECTION AND MAINTENANCE:

If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may
lead to serious injury or death. Always observe the following:
Checks after operation (with engine stopped)
Have any inspection and maintenance points been forgotten?
Have all inspection and maintenance items been performed correctly?
Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside the machine and get caught in the lever linkage mechanism.
Are there any leakage of coolant or oil? Have all nuts and bolts been tightened?
Check when the engine is running
See "TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING (PAGE 2-34)" in the section on
safety for checking when the engine is running. Pay attention to safety.
Check if the inspected and maintenance area is operating normally.
Increase the engine speed to check for fuel and oil leakage.
4-3
.
OUTLINES OF SERVICE MAINTENANCE
OUTLINES OF SERVICE
Always use Komatsu genuine parts for replacement parts, grease or oil.
When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all the
old oil and fill completely with the new oil. Always replace the filter at the same time. (There is no problem if the
small amount of oil remaining in the piping mixes with the new oil.)
Unless otherwise specified, when the machine is shipped from the factory, it is filled with the oil and coolant listed
in the table below.
Item Type
Engine oil pan Engine oil EO15W40DH (Komatsu genuine parts)
Transmission case Power train oil TO10 (Komatsu genuine parts)
Hydraulic oil system Power train oil TO10 (Komatsu genuine parts)
Axle Axle oil AXO80 (Komatsu genuine parts)
Radiator Supercoolant AF-NAC (density: 30% or above) (Komatsu genuine parts)
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
OIL
Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in the
Operation and Maintenance Manual. Even if the oil is not dirty, always change the oil at the specified interval.
Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities (water,
metal particles, dirt, etc.) from getting in.
The majority of problems with the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified capacity of oil.
Having too much oil or too little oil are both causes of problems.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
When changing the oil, always replace the related filters at the same time.
We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, consult your Komatsu distributor.
When using commercially available oil, it may be necessary to reduce the oil change interval.
We recommend that you use the Komatsu oil clinic to perform a detailed checks of the characteristics of the oil.
4-4
.
MAINTENANCE OUTLINES OF SERVICE
FUEL
To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank
after completing the day's work.
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperatures below -15°C
(5°F)), so it is necessary to use the fuel that is suitable for the temperature.
Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from
the fuel tank.
If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.
COOLANT AND WATER FOR DILUTION

The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4,000
hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
When diluting the coolant, use distilled water or tap water (soft water).
Natural water, such as a river water or well water (hard water), contains large amounts of minerals (calcium,
magnesium, etc.), and this makes it easier for scale to form inside the engine or radiator. Once scale is deposited
inside the engine or radiator, it is extremely difficult to remove. It also causes overheating due to poor heat
exchange, so when you dilute the coolant, we recommend that you use water with an overall hardness of less
than 100 PPM.
When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
Undiluted coolant is flammable, so be sure to keep it away from flame.
The ratio of Supercoolant (AF-NAC) to water differs according to the ambient temperature.
For details of the ratio when mixing, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-21)".
Supercoolant (AF-NAC) may be supplied already mixed. In such cases, never dilute with water.
If the engine overheats, wait for the engine to cool before adding coolant.
If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air entering
the coolant.
GREASE
Grease is used to prevent seizure and noises at the joints.
This construction equipment is used under heavy-duty conditions. Always use the recommended grease and
follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance
Manual.
Grease fittings not included in the maintenance section are grease fittings for overhaul, so they do not need
grease.
If any part becomes stiff after being used for long time, add grease.
Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause
wear of the rotating parts.
4-5
.
OUTLINES OF SERVICE MAINTENANCE
PERFORMING KOWA (Komatsu Oil Wear Analysis)

KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the
oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other
problems.
We strongly recommend you to use this service. The oil analysis is performed at actual cost, so the cost is low, and
the results of the analysis are reported together with recommendations which will reduce repair costs and machine
downtime.
KOWA ANALYSIS ITEMS

Measurement of density of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to
measure the density of iron, copper, and other metal wear
particles in the oil.
Measurement of quantity of particles

This uses a PQI (Particle Quantifier Index) measurer to
measure the quantity of iron particles of 5 μm or more, enabling
early detection of failures.
Others
Measurements are made of items such as the ratio of water, coolant, and fuel in the oil, and dynamic viscosity,
if necessary, to enable a highly precise diagnosis of the machine and the components' condition.
OIL SAMPLING
Sampling interval
500 hours
Precautions when sampling
Make sure that the oil is well mixed before sampling.
Perform sampling at regular fixed intervals.
Do not perform sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, contact your Komatsu distributor.
STORING OIL AND FUEL

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

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.
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and
checking battery fluid level.
Never install any electric components other than those specified by Komatsu.
External electro-magnetic interference may cause malfunction of the control system controller, before installing
a radio receiver or other wireless equipment, consult your Komatsu distributor.
When working at the seashore, carefully clean the electric system to prevent corrosion.
The optional power source must never be connected to the fuse, starting switch, or battery relay.
4-7
.
WEAR PARTS MAINTENANCE
WEAR PARTS
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 for the latest part number when ordering parts.
WEAR PARTS LIST

The parts in parentheses are to be replaced at the same time.
Item Part No. Part Name Q'ty Replacement frequency

Engine oil filter 6742-01-4540 Cartridge 1 EVERY 500 HOURS
Fuel filter 600-311-8321 Cartridge 1 EVERY 500 HOURS
Water separator 07000-12065 O-ring 1 -
Transmission oil filter 714-07-28713 Cartridge 1 EVERY 1000 HOURS
Transmission strainer 07000-15085 O-ring 1 EVERY 1000 HOURS
Corrosion resistor 600-411-1191 Cartridge 1 EVERY 1000 HOURS
07063-01210 Element 1
Hydraulic filter EVERY 2000 HOURS
(07000-15210) (O-ring) (1)
Hydraulic tank breather 421-60-35170 Element 1 EVERY 2000 HOURS
Air cleaner 600-185-5100 Element ass'y 1 -
Fresh 427-07-22120 Element 1 EVERY 2000 HOURS
Air conditioner filter
Recirc 20Y-979-6261 Element 2 EVERY 2000 HOURS
20Y-60-11430 Accumulator
PPC accumulator 1 EVERY 4000 HOURS
(07002-12034) (O-ring)
424-815-1111 Center edge 1
424-815-1131 Side edge 2
Standard
(02090-11485) (Bolt) (14) -
type
(02290-11422) (Nut) (14)
(01643-32260) (Washer) (14)
424-T79-1110 Center edge 2
424-T79-1120 Side edge 2
Bolt on cutting edge
Long life type (02090-11485) (Bolt) (14) -
(02290-11422) (Nut) (14)
(01643-32260) (Washer) (14)
421-838-1110 Edge 7
Segment (02091-11600) (Bolt) (14)
-
type (02290-11625) (Nut) (14)
(01643-22460) (Washer) (14)
4-8
.
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT
RECOMMENDED FUEL, COOLANT, AND LUBRICANT

Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment
and components.
In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the
instructions in this Operation and Maintenance Manual.
Failure to follow the Operation and Maintenance Manual may result in shortened life or excess wear of the engine,
power train, cooling system, and/or other components.
Commercially available lubricant additives may be good for the machine, but they may also cause harm.
Komatsu does not recommend any commercially available lubricant additive.
Use the oil recommended according to the ambient temperature in the chart below.
Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill amount of oil
means the amount of oil needed to refill the system during inspection and maintenance.
When starting the engine in temperatures below 0°C (32°F), be sure to use the recommended multi-grade oil,
even if the ambient temperature may become higher during the course of the day.
If the machine is operated at a temperature below -20°C (-4°F), a separate device is needed, so consult your
When the fuel sulfur content is less than 0.5%, change the engine oil according to the period inspection table
given in this Operation and Maintenance Manual.
If the fuel sulfur content is more than 0.5%, change the oil according to the following table.
Fuel sulfur content Engine oil change interval

0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
4-9
.
RECOMMENDED FUEL, COOLANT, AND LUBRICANT MAINTENANCE
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
4 - 10
.
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT
Reservoir Axle
Engine oil Transmission Hydraulic Cooling
(front and rear) Fuel tank
pan case system system
Capacity (each)
Liters 37 62 186 38 36 300
Specified
US gal 9.78 16.38 49.14 10.04 9.51 79.26
Liters 32 54 129 38 - -
Refill
US gal 8.45 14.27 34.08 10.04 - -
Note 1: Oil used in the power train is different from engine oil. Use an appropriate oil recommended for each
application.
Note .2: Axle oil AXO80 has the function of preventing squealing from the brakes and LSD (Limited Slip Differential).
If only AXO80 is recommended, use Komatsu genuine AXO80 or equivalent.
Note .3: When the ambient temperature is higher than 45°C (113°F) and the machine operation hour is longer than
12 hours/day, then the use of EO50-CD instead of AXO80 is recommended.
Squealing of the brakes may occur with EO50-CD, but there is no problem with the brake performance or
durability.
Note .4: If the machine is equipped with an automatic greasing system, see "HANDLING AUTO-GREASING
SYSTEM (PAGE 6-38)".
Note .5: Hyper grease (G2-T, G2-TE) has a high performance.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins
and bushings, the use of G2-T or G2-TE is recommended.
Note .6: Supercoolant (AF-NAC)

1) The coolant has the important function of preventing corrosion as well as preventing freezing.
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
2) For details of the ratio when diluting super coolant with water, see "CLEAN INSIDE OF COOLING SYSTEM
(PAGE 4-21)".
When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Supercoolant
(AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C (14°F). (never dilute with water)
3) To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 68%.
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN

KOMATSU GENUINE OIL
When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifications,
refer to the Komatsu web page or consult your Komatsu distributor.
4 - 11
.
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS MAINTENANCE
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

TORQUE LIST
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and
this will cause failure of the machine or problems with operation.
Always pay careful attention when tightening parts.
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
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) Nm kgm lbft Nm kgm lbft
6 10 13.2 1.35 9.8 11.8 to 14.7 1.2 to 1.5 8.7 to 10.8
8 13 31 3.2 23.1 27 to 34 2.8 to 3.5 20.3 to 25.3
10 17 66 6.7 48.5 59 to 74 6.0 to 7.5 43.4 to 54.2
12 19 113 11.5 83.2 98 to 123 10.0 to 12.5 72.3 to 90.4
14 22 172 17.5 126.6 153 to 190 15.5 to 19.5 112.1 to 141.0
16 24 260 26.5 191.7 235 to 285 23.5 to 29.5 170.0 to 213.4

18 27 360 37.0 267.6 320 to 400 33.0 to 41.0 238.7 to 296.6
20 30 510 52.3 378.3 455 to 565 46.5 to 58.0 336.3 to 419.5
22 32 688 70.3 508.5 610 to 765 62.5 to 78.0 452.1 to 564.2
24 36 883 90.0 651.0 785 to 980 80.0 to 100.0 578.6 to 723.3
27 41 1295 132.5 958.4 1150 to 1440 118.0 to 147.0 853.5 to 1063.3

30 46 1720 175.0 1265.8 1520 to 1910 155.0 to 195.0 1121.1 to 1410.4
33 50 2210 225.0 1627.4 1960 to 2450 200.0 to 250.0 1446.6 to 1808.3
36 55 2750 280.0 2025.2 2450 to 3040 250.0 to 310.0 1808.3 to 2242.2
39 60 3280 335.0 2423.1 2890 to 3630 295.0 to 370.0 2133.7 to 2676.2
Apply the following table for Hydraulic Hose.
Width Tightening torque

Nominal -
across
No. of Target value Permissible range
flats (b)
threads (a)
(mm) Nm kgm lbft Nm kgm lbft
9/16 -18UNF 19 44 4.5 32.5 34 to 63 3.5 to 6.5 25.3 to 47.0
11/16 -16UN 22 74 7.5 54.2 54 to 93 5.5 to 9.5 39.8 to 68.7
13/16 -16UN 27 103 10.5 75.9 84 to 132 8.5 to 13.5 61.5 to 97.6
1 -14UNS 32 157 16.0 115.7 128 to 186 13.0 to 19.0 94.0 to 137.4
13/16 -12UN 36 216 22.0 159.1 177 to 245 18.0 to 25.0 130.2 to 180.8
4 - 12
.
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

For using the machine safely for an extended period of time, you must periodically replace the safety critical and fire
prevention-related parts listed in the table of 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 important to
ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the periodic
replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time as
the hoses.
Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose
clamps and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Ask your Komatsu distributor to replace the critical parts.
No. Safety critical parts for periodic replacement Q'ty Replacement interval
1 Fuel hose (fuel tank - water separator) 1
2 Fuel hose (water separator - priming pump) 1
3 Fuel return hose (injection pump - fuel tank) 1
4 Fuel spill hose (injector - injector) 5
5 Fuel spill hose (unit injector - fuel tank) 1
6 Steering hose (pump - steering valve) 1
7 Steering hose (steering valve - steering cylinder) 4
8 Steering hose (steering valve - hydraulic tank) 2
9 Brake hose (pump - accumulator charge valve) 2
10 Brake hose (accumulator charge valve - check valve) 1
11 Brake hose (check valve - tandem valve) 2
12 Brake hose (check valve - single valve) 1
13 Brake hose (check valve - accumulator P.P port) 1 Every 2 years or
every 4000 hours
14 Brake hose (tandem valve - front brake) 2
15 Brake hose (tandem valve - rear brake) 2
16 Brake hose (single valve - tandem valve) 1
17 Brake hose (tandem valve - drain block) 1
18 Brake hose (single valve - drain block) 1
19 Brake hose (drain block - hydraulic tank) 1
Brake hose (brake accumulator - reduction valve for emergency parking
20 1
brake cancel)
Brake hose (transmission valve - reduction valve for emergency parking
21 1
brake cancel)
22 Brake hose (charge valve drain - hydraulic tank) 1
23 Accumulator (For PPC) 1
24 Alarm 2
25 Seat belt 1 Every 3 years
4 - 13
.
MAINTENANCE SCHEDULE CHART MAINTENANCE
MAINTENANCE SCHEDULE CHART

MAINTENANCE SCHEDULE CHART
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
CHANGE TRANSMISSION OIL FILTER CARTRIDGE 4- 53
REPLACE HYDRAULIC TANK FILTER ELEMENT 4- 56
INITIAL 1000 HOURS SERVICE (ONLY AFTER THE FIRST 1000 HOURS)
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 62
WHEN REQUIRED
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT 4- 17
CLEAN INSIDE OF COOLING SYSTEM 4- 21
CHECK WATER SEPARATOR 4- 24
CHECK TRANSMISSION OIL LEVEL, ADD OIL 4- 25
CHECK AXLE OIL LEVEL, ADD OIL 4- 26
CHECK AXLE CASE BREATHER 4- 27
CLEAN CONDENSER OF AIR CONDENSER 4- 28
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID 4- 28
CLEAN RADIATOR FINS AND COOLER FINS 4- 29
CHECK ELECTRICAL INTAKE AIR HEATER 4- 32
TURN, REPLACE BOLT ON CUTTING EDGE 4- 33
REPLACE BUCKET TEETH 4- 34
CHECK AIR CONDITIONER 4- 36
REPLACE SLOW-BLOW FUSE 4- 37
CHECKING FUNCTION OF ACCUMULATOR 4- 38
SELECTION AND INSPECTION OF TIRES 4- 39

DRAIN WATER, SEDIMENT FROM FUEL TANK 4- 42

LUBRICATE REAR AXLE PIVOT PIN 4- 43
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL 4- 43
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER 4- 44

CHECK BATTERY ELECTROLYTE LEVEL 4- 45
CHECK PARKING BRAKE 4- 47
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST 4- 47
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN 4- 48
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER 4- 48
LUBRICATING 4- 50
4 - 14
.
MAINTENANCE MAINTENANCE SCHEDULE CHART

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 51
REPLACE FUEL FILTER CARTRIDGE 4- 52

CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN
STRAINER 4- 53
CLEAN TRANSMISSION CASE BREATHER 4- 54
LUBRICATING 4- 54
CHECK TIGHTENING PARTS OF TURBOCHARGER 4- 55
CHECK PLAY OF TURBOCHARGER ROTOR 4- 55
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT 4- 55
REPLACE CORROSION RESISTOR CARTRIDGE 4- 55

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT 4- 56
REPLACE HYDRAULIC TANK BREATHER ELEMENT 4- 58
CHANGE AXLE OIL(*) 4- 59
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER 4- 59
CLEAN PPC CIRCUIT STRAINER 4- 60
CLEAN ENGINE BREATHER ELEMENT 4- 60
CHECK BRAKE DISC WEAR 4- 61
CHEK ALTERNATOR, STARTING MOTOR 4- 62
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 62
CLEAN AND CHECK TURBOCHARGER 4- 62
CHECK INJECTOR 4- 62
CHECK VIBRATION DAMPER 4- 63
*: 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- 64
CHECK WATER PUMP 4- 65
CHECK AIR CONDITIONER COMPRESSOR, ADJUST 4- 65
REPLACE INJECTOR ASSEMBLY 4- 65
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER 4- 65
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 4- 65

REPLACE HIGH-PRESSURE PIPING CLAMP 4- 66
REPLACE FUEL SPRAY PREVENTION CAP 4- 66
4 - 15
.
SERVICE PROCEDURE MAINTENANCE
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE
Perform the following maintenance only after the first 250 hours.
Change transmission oil filter cartridge

Replace hydraulic tank filter element
For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS and 2000 HOURS
SERVICE.
INITIAL 1000 HOURS SERVICE

Carry out the following maintenance only after the first 1000 hours.
Check engine valve clearance, adjust
For details of the method of replacing or maintaining, see the section on EVERY 2000 HOURS SERVICE.
4 - 16
.
MAINTENANCE SERVICE PROCEDURE
WHEN REQUIRED
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT

WARNING
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it.
Always stop the engine before carrying out these operations.
When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use protective eyeglasses, 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 caution 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 efficiency will drop.
In addition, the frequency of dirt stuck to the element falling inside the
inner element will increase.
It is also possible to check the condition of the air cleaner by using

the dust indicator installed to the air cleaner.
If the yellow piston in the dust indicator display portion enters the
red (7.5 kPa (0.0765 kg/cm2, 1.1 PSI)) position, clean the element.
4 - 17
.
CLEANING OUTER ELEMENT

1. Open the top cover at the front of the engine side cover on the
right side of the machine.
2. Remove 3 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. Clean the interior of the air cleaner body, cover (3) and
vacuator valve (6).
NOTICE
The inner element must not be used again even after cleaning. When
replacing the outer element, replace the inner element at the same time.
5. Direct dry compressed air (Max. 0.69 MPa (7 kg/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.
4 - 18
.
6. If small holes or thinner parts are found on the element when

it is checked by shining a light through it after cleaning, 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.
7. Set the cleaned outer element in position, then secure cover (3) with mounting clips (2).
8. Press the dust indicator button to return the yellow piston to its
original position.
9. Close the top cover at the front of the engine side cover on the right side of the machine.
After cleaning, if the air cleaner clogging caution lamp lights up immediately or the yellow piston reaches the red
line (7.5 kPa), replace the inner and outer elements.
4 - 19
.
REPLACING ELEMENT
1. Open the top cover at the front of the engine side cover on the
right side of the machine.
2. Remove 3 clips (2), then remove cover (3).
3. Remove outer element (4).

Do not remove inner element (5) at this time, however.
4. Clean the inside of the air cleaner body and dust cup.
5. Remove inner element (5), then install a new inner element immediately.
6. Fit new outer element (4), replace O-ring (7) with a new part, install cover (3), then secure with clips (2).
7. Press the dust indicator button to return the yellow piston to its
original position.
8. Close the top cover at the front of the engine side cover on the right side of the machine.
4 - 20
.
CLEAN INSIDE OF COOLING SYSTEM

WARNING
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, then turn the cap slowly to
release the pressure.
Start the engine and flush the system. Before standing up or leaving the operator's seat, set the work equipment lock lever to
LOCK position.
For details of starting the engine, see "CHECK BEFORE STARTING ENGINE, ADJUST (PAGE 3-90)" and "STARTING ENGINE
(PAGE 3-106)" in the OPERATION section of the Operation and Maintenance Manual.
When the undercover is removed, there is danger of touching the fan.
Never enter 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.
Interval of cleaning inside of cooling system

Antifreeze coolant Replacing corrosion resistor
and changing antifreeze coolant
Komatsu supercoolant Every two years or every 4000 hours

(AF-NAC) whichever comes first Every 1000 hours
and when cleaning the inside
of the cooling system
Permanent type antifreeze Every year (autumn) or every 2000 hours and when changing coolant.
(All-season type, *) whichever comes first.
*: Permanent type antifreeze shall meet the requirements of ASTM D3306-03.
Stop the machine on level ground when cleaning or changing the coolant.
The coolant has the important function of preventing corrosion as well as preventing freezing.
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 64%.
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing
table given below.
It is actually better to estimate and temperature about 10°C (18°F) lower when deciding the mixing ratio.
The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume
(antifreeze/total amount of coolant x 100).
The freezing temperature of undiluted antifreeze is -15°C (5°F). Do not store undiluted antifreeze at a temperature
of below -15°C (5°F).
4 - 21
.
Mixing rate of water and antifreeze
Min. atmospheric °C Above -10 -15 - 20 - 25 - 30

temperature °F Above 14 5 -4 - 13 - 22
Liters 10.8 12.6 14.4 16.2 18.0
Amount of antifreeze
US gal 2.85 3.33 3.80 4.28 4.76
Liters 25.2 23.4 21.6 19.8 18.0
Amount of water
US gal 6.66 6.18 5.71 5.23 4.75
Ratio % 30 36 41 46 50
WARNING
Antifreeze coolant is flammable, so keep it away from open flame.
Antifreeze coolant is toxic. When removing the drain plug, be careful not to get water containing antifreeze coolant on you. If it
gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.
Use antifreeze and appropriate water for diluting (for details, see "COOLANT AND WATER FOR DILUTION (PAGE
4-5)")
We recommend use of an antifreeze density gauge to control the mixing proportions.
Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant.
Prepare a hose to supply coolant and water.
1. Stop the engine and tighten 2 valves (1) of the corrosion
resistor.
2. Check that the cooling water temperature has gone down

enough to make it possible to touch the radiator cap surface by
hand, then turn radiator cap (2) slowly until it contacts the
stopper to release the pressure.
3. Following this, push radiator cap (2), turn it until it contacts the
stopper, then remove it.
4 - 22
.
4. Set a container in position to catch drained antifreeze mixture,

then open valve (3) under the left side of the fuel tank and drain
valve (4) at the side of the cylinder block to drain cooling water.
5. After draining the coolant, close drain valves (3) and (4), and fill
with city water.
6. When the radiator is full, start the engine, and run it at low idle.
Keep the engine running at low idle for 10 minutes until the
coolant temperature reaches more than 90°C (194°F).
7. Stop the engine, open drain valves (3) and (4), drain the water,
then tighten them again.
8. After draining the water, clean it with detergent liquid.
For the cleaning method, follow the instruction for the detergent liquid.
9. Replace the corrosion resistor, then open 2 valves (1).
For details of the procedure for replacing the corrosion resistor, see "REPLACE CORROSION RESISTOR
CARTRIDGE (PAGE 4-55)".
10. Add coolant mixed with antifreeze until it overflows from the water filler.
Decide the proportions of antifreeze and water according to the table for the mixing rate of water and antifreeze.
11. To remove the air in the coolant, run the engine at Low idle (MIN) for 5 minutes, and then run at High idle (MAX)
for a further 5 minutes. (When doing this, leave the radiator cap off.)
12. Drain the coolant from sub-tank (5), clean the inside of the
sub-tank, then add water until the coolant level is between the
FULL and LOW marks.
13. Stop the engine, wait for approximately 3 minutes, then add
coolant until the coolant level is near the coolant filler port, and
tighten the cap. Check the coolant level and add coolant if
necessary.
4 - 23
.
CHECK WATER SEPARATOR

WARNING
The engine is at high temperature immediately after the machine has been operated. Wait for the engine to cool down before
replacing the filter.
Do not bring fire or sparks near the fuel.
1. Open the engine side cover on the right side of the machine.
2. Check the water separator to see that a red ring inside has
come up to the standard line.
3. If red ring (1) has come up to the standard line, carry out the
operation from Step 4 below.
4. Prepare a container to catch the drained fuel and set it under
the water separator.
5. Loosen drain valve (1) at the bottom of the water separator and
drain the water and fuel into the container.
6. Loosen ring nut (2), then remove element cup (3).
7. Remove element (4) from the separator base.
8. Wash the interior of filter element (4) and element cup (3) with
clean fuel.
9. Check element (4) and replace it if it is damaged.
10. Clean the water separator base, then fill washed element cup
(3) with clean fuel and install it on the water separator base.
Be sure to use clean fuel for filling the element cup and take
care so that no dust will mix with it.
REMARK
Be careful not to lose the O-ring, float, or spring. Be sure to
assemble them after washing.
11. Install element (4) in the reverse sequence to the removing

process mentioned in the Step 6 nad 7.
The specified tightening torque of ring nut (2):
40 ± 3 Nm (4.1 ± 0.3 kgm , 29.7 ± 2.2 lbft)
If the ring is loose, it will cause leakage of fuel, so always
tighten it to the specified torque.
12. After installing filter element cup (3), bleed air in the following
manner.
4 - 24
.
13. Loosen air bleed plug (5) of the fuel filter.

14. Pump priming pump (6) until no more bubbles come out with
the fuel from air bleeder (5).
CHECK TRANSMISSION OIL LEVEL, ADD OIL

WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature
to go down before starting the work.
Carry out this procedure if there is any sign of oil on the transmission case, or if there is oil mixed with the cooling
water.
1. Start the engine and run it for at least 5 minutes.
2. Open the cap of oil filler port (F), remove dipstick (G), and wipe
the oil off with a cloth.
3. Fully insert dipstick (G) into dipstick pipe, then remove it.
4. The oil level should be between H and L marks on dipstick (G).

If the oil level is below L mark, add oil through oil filler port (F).
5. If the oil is above H mark, drain the excess oil from drain plug
(P), and check the oil level again.
6. If the oil level is correct, insert dipstick (G) in the dipstick guide,
then tighten the cap.
4 - 25
.
CHECK AXLE OIL LEVEL, ADD OIL

WARNING
When checking the oil level, apply the parking brake and secure the front and rear frames with the frame lock bar.
After stopping the engine, the parts and oil are at a high temperature. Wait for the temperature to go down before starting the
operation.
Perform this procedure if there is any sign of oil on the axle case.
Inspect the machine on a horizontal surface.
(If the road surface is at an angle, the oil level cannot be checked correctly.)
1. Stop the engine and remove oil level plug (1).
REMARK
Remove the mud and dirt from around plug (1), then remove the
plug.
2. With cloth, wipe off any oil adhering to the dipstick attached to
plug (1).
4 - 26
.
3. Set the dipstick (G) as shown in the right figure.

4. The oil level is correct when it is between the two lines provided
on the oil level gauge.
If the oil level does not reach the lower line, add axle oil through
filler port (F).
REMARK
For axles with ASD (Limited-Slip Differential), the brand of
lubricating oil is different. Use the specified lubricating oil.
5. If the oil level is above the upper line, drain off the excess oil
through drain plug (P) and check the oil level again.
6. If the oil level is correct, install plug (1).
Tightening torque: 127 to 177 Nm {13 to 18 kgm, 94.0 to 130.2
lbft}
CLEAN AXLE CASE BREATHER

WARNING
When cleaning the axle breather, apply the parking brake and secure the front and rear frames with the frame lock bar.
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 2 places (front
and rear).
After removing the breather, take steps to prevent dirt or dust from
entering the mount.
4 - 27
.
CLEAN AIR CONDITIONER CONDENSER

WARNING
Do not wash the condenser with a steam cleaner. There is danger that the condenser could overheat.
If high-pressure water hits your body directly or dirt is sent flying, there is danger of personal injury. Always wear protective
glasses, dust mask, and other protective equipment.
If there is mud or dust on the air conditioner condenser, clean it with water.
If the water pressure is too high, the fins may get deformed. When washing with a high pressure washing machine,
apply the water from a reasonable distance.
WASHING METHOD
1. Open top cover (1) at the front of the engine hood.
2. Remove four bolts (3) on top of condenser (2).
3. Tilt condenser (2) back, holding its upper part. It will swing with
pin (4) at the lower part as a fulcrum.
4. Wash with water from the top.
5. Pull condenser (2) back to the original position and fit bolt (3).
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID

(if equipped)
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 - 28
.
CLEAN RADIATOR FINS AND COOLER FINS

WARNING
Never open the engine side cover when the engine is running. Stop the engine completely before starting the cleaning
operation.
If compressed air, pressurized water, or steam hits your body directly, or causes dirt to fly, it may lead to personal injury.
Always wear protective eyeglasses, dust mask, or other protective equipment.
Clean the radiator fins if any mud or dirt is stuck to the radiator.
CLEAN FINS BY ROTATING COOLING FAN IN REVERSE
NOTICE
When rotating the fan in reverse, be careful of flying dust and take steps to
prevent cloth or other objects from getting caught in the fan.
On jobsites where it is easy for dirt to stick to the radiator or cooler,

turn cooling fan reverse rotation switch (1) ON to rotate the fan in
reverse. This will blow off the dirt and dust stuck to the radiator or
cooler, and can extend the cleaning interval.
METHOD OF ROTATING FAN IN REVERSE
NOTICE
When the engine is running, even if the switch is pressed, the direction of rotation of the fan does not change, but the cooling
fan reverse rotation pilot lamp on the machine monitor flashes. Stop the engine, then operate the switch.
When the fan is rotating in reverse, the pilot lamp on the machine monitor lights up. Do not carry out operations while the pilot
lamp is lighted up. The machine will be unable to display its performance fully and it may lead to overheating. For normal
operations, always use the fan rotating in the normal direction.
If the engine has to be stopped when the fan is rotating in reverse, run the engine at low idle, then stop it.
1. Turn the starting switch to the OFF position and stop the engine.
2. Turn the starting switch to ON position.
3. Set cooling fan reverse rotation switch (1) to position (a) (ON).
4 - 29
.
4. Check that the pilot lamp inside the switch and the cooling fan
reverse rotation pilot lamp on the machine monitor are lighted
up. At the same time, "COOLING FAN REVERSE" is
displayed on the character display, and the fan is set to reverse
rotation.
5. Turn the key in the starting switch to the START position and
start the engine.
The cooling fan will rotate in reverse.
6. Run the engine at High idle (MAX).

Select the time for running the engine at High idle (MAX) as follows according to the condition of clogging.
Normal clogging: 1 to 2 minutes
Excessive clogging: 2 to 3 minutes
7. After completing the cleaning, run the engine at Low idle (MIN) for approximately 10 seconds.
9. After the fan stops turning, loosen wing bolt (2) and remove
wing bolt (3) to open cleaning cover (4).
10. Insert the air nozzle and blow the dirt out to the front of the
machine.
REMARK
Steam or water can be used instead of compressed air.
11. After blowing dirt out, install cleaning cover (4).
12. Run the engine at low idle.

13. Turn the key in the starting switch to the OFF position and stop the engine.
14. Turn starting switch key to ON position.
15. Set cooling fan reverse rotation switch (1) to position (b) (OFF)
to cancel the reverse rotation.
16. Check the rubber hose. Replace with a new one if the hose is
found to have cracks or to be hardened by aging.
Also, check hose clamps for looseness.
4 - 30
.
CLEAN FINS WITH COMPRESSED AIR

Tilt aftercooler (1) at the top front face of the radiator, swing oil
cooler (2) at the bottom, then insert the steam jet nozzle through
the gap and clean the fins.
METHOD OF TILTING AND SWINGING COOLER

2. Pull lever (3) down to release the lock, then tilt aftercooler (1).
Turn the knob (4) counterclockwise to release the lock, then
swing oil cooler (2).
If necessary, band (5) can be fitted to oil cooler (2) to hold it in
position after swinging it.
3. Use the steam jet nozzle to blow out the mud, dirt, or leaves
clogging the radiator fins or cooler fins.
NOTICE
If the steam jet nozzle is brought too close to the radiator fins, it may damage the fins, so keep the nozzle a suitable distance away
from the fins when cleaning.
4. Check the rubber hose. Replace with a new one if the hose is found to have cracks or to be hardened by aging.
Also, check hose clamps for looseness.
5. Do as follows to blow out the mud or dirt that has fallen to the bottom.
6. Loosen wing bolt (6) and remove wing bolt (7) to open cleaning
cover (8).
7. Insert the air nozzle and blow the dirt out to the front of the
machine.
REMARK
Steam or water can be used instead of compressed air.
8. After blowing dirt out, install cleaning cover (8).
9. After completing the cleaning, push the bottom of aftercooler (1) to lock it, then push the front of oil cooler (2) to
lock it.
Check that they are both securely locked in position.
4 - 31
.
ADJUSTING RUBBER STOPPER FOR AFTERCOOLER

If aftercooler (1) moves even when it is locked, adjust rubber stopper (2) as follows.
1. Push the bottom of aftercooler (1) to lock it securely.
2. Loosen locknut (3) of rubber stopper (2).

3. Adjust the height of rubber stopper (2) so that aftercooler (1)
does not move.
REMARK
Push rubber stopper (2) to adjust so that it contacts aftercooler (1).
4. Tighten locknut (3).
5. There is one rubber stopper (2) each on the left and right, so repeat Steps 1 - 4 to adjust the rubber stopper on
the opposite side.
6. After adjusting the rubber stopper on the left and right, push the bottom of aftercooler (1) and check that it does
not move.
AFTERCOOLER TILT SWITCH

(if equipped)
For machines with the optional equipment, Step 2 of the method for
tilting and swinging the cooler can be used to tilt the aftercooler
electrically.
Press aftercooler switch on the left side of the engine room to tilt
the aftercooler electrically approx. 17 degrees; press (b) to return
the aftercooler to its original position.
CHECK ELECTRICAL INTAKE AIR HEATER

Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air
heater repaired or checked for dirt or disconnections.
4 - 32
.
TURN, REPLACE BOLT-ON CUTTING EDGE

WARNING
It is dangerous if the work equipment moves by mistake during the turning or replacement operation.
Set the work equipment in a stable condition, stop the engine, then set the work equipment lock lever securely to the LOCK
position.
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.
Set the bottom of bucket to be level, and put a block under the
bucket at the center.
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 turning
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: 745 ± 108 Nm {76 ± 11 kgm, 549.7 ± 79.6 lbft}
6. Tighten the mounting bolts again after operating for several hours.
4 - 33
.
REPLACE BUCKET TEETH

(if equipped)
ONE-PIECE TOOTH
When the bucket teeth are worn, replace them as follows.
2. Remove the bolt and nuts (1) and (2), then remove bucket
tooth (3).
3. Clean the installation surface of bucket tooth (3).
4. Install new teeth to the bucket.
When doing this, insert shims so that there is no clearance
between the teeth and the top surface of the bucket.
Continue to add shims until it becomes impossible to add a 0.5
mm (0.02 in) shim.
If the mounting surface is worn, correct the mounting surface
before installing the teeth.
5. To prevent any gap from forming between the teeth and tip of the bucket, tighten bolts and nuts (1) and (2)
temporarily, then hit the tip of the teeth with a hammer.
Tightening torque of mounting bolt (1): 637 ± 853 Nm {65 ± 87 kgm, 470.1 ± 629.3 lbft}
(2): 618 Nm {63 kgm, 455.7 lbft}
6. After operating the machine for a few hours, tighten the mounting bolts again.
4 - 34
.
BUCKET WITH TIP TOOTH
WARNING
If the pin is hit out with strong force, there is danger that the pin may fly out. Check that there is no one in the surrounding area.
There is danger of pieces flying during the replacement operation, so always wear protective clothing, such as protective
eyeglasses and gloves.
Replace the teeth before they wear down as far as the adapter.
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.
5. If mounting bolts (4) or (5) of adapter (3) are loose, tighten them.
Tightening torque of mounting bolt (4): 637 ± 853 Nm (65 ± 87 kgm, 470.1 ± 629.3 lbft)
(5): 618 Nm (63 kgm, 455.7 lbft)
4 - 35
.
CHECK AIR CONDITIONER

CHECK LEVEL OF REFRIGERANT (GAS)
WARNING
If the refrigerant used in the air conditioner gets into your eyes or on your
hands, it may cause loss of sight or frostbite. Do not touch the refrigerant.
Never loosen any part of the refrigerant circuit.
Do not bring any open flame close to any point where the refrigerant gas is
leaking.
If there is a lack of refrigerant (gas), the cooling performance will be

poor. When operating the air conditioner at high speed with the
engine at full throttle, use the receiver sight glass (inspection
window) to check the condition of the refrigerant gas
(Hydrofluorocarbons HFC-134a) flowing in the refrigerant circuit.
No bubbles in refrigerant flow: Suitable
Some bubbles in flow
(bubbles pass continuously): Lack of refrigerant
Colorless, transparent: No refrigerant
REMARK
When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributors to have refrigerant
added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
OPERATING THE AIR CONDITIONER OFF-SEASON

Even during the off-season, operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all
parts of the compressor.
4 - 36
.
REPLACE SLOW BLOW FUSE
NOTICE
Always turn the power OFF when replacing the slow blow fuse (turn the
starting switch to the OFF position).
Always replace the slow blow fuse with a fuse of the same capacity.
1. 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 protrusion
(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 - 37
.
CHECKING FUNCTION OF ACCUMULATOR

For details of handling the accumulator, see Section "ACCUMULATOR (PAGE 2-35)".
ACCUMULATOR FOR TRAVEL DAMPER

When the travel damper switch is ON, the hydraulic spring effect of the accumulator absorbs the up-and-down
motion of the machine during travel and reduces the swaying.
Drive the machine and compare the up-and-down movement of the machine during travel when the travel damper
switch is ON and when it is OFF.
If there is no change in the up-and-down movement of the machine, the gas pressure in the accumulator has
probably dropped.
Please contact your Komatsu distributor to have the accumulator inspected.
REMARK
Carry out the inspection when the machine is traveling at a speed of at least 10 km/h (6.2 MPH). Even if the travel
damper switch is ON, the travel damper is not actuated if the travel speed is less than 10 km/h (6.2 MPH).
ACCUMULATOR FOR BRAKE DAMPER

When the brake pedal is depressed, the hydraulic spring effect of the accumulator actuates the brake smoothly.
If any change is felt in the smoothness of the brake operation during daily operations, the gas pressure in the
accumulator has probably dropped.
REMARK
Even if there is any change in the smoothness, there is no drop in the braking force or brake performance.
4 - 38
.
SELECTION AND INSPECTION OF TIRES

WARNING
If a tire or a rim is handled improperly, the tire may burst or may be
damaged and the rim may be broken and scattered, and that can cause
serious injury or death.
Since maintenance, disassembly, repair and assembly of the tires and
rims require special equipment and skill, be sure to ask a tire repair
shop to do the work.
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
following table.
Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when
using optional tires.
Tire size Maximum load [kg (lb)]

Standard Front and Rear 20.5-25-16PR 7,720 (17,023)
Option Front and Rear 23.5-25-16PR 9,095 (20,054)
4 - 39
.
CHECK INFLATION PRESSURE OF TIRES
WARNING
When inflating a tire, check that no one will enter the working area. Use an
air chuck which has a clip and which can be fixed to the air valve.
While inflating the tire, check the inflation pressure occasionally so that
it will not rise too high.
If the rim is not fitted normally, it may be broken and scattered while the
tire is inflated. To ensure safety, place a guard around the tire and do not
work in front of the rim but work on the tread side of the tire.
Abnormal drop of inflation pressure and abnormal 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: 0.34 MPa (3.5 kg/cm2, 49.7 PSI)
Standard 20.5-25-16PR
Rear Tire: 0.34 MPa (3.5 kg/cm2, 49.7 PSI)
Front Tire: 0.30 MPa (3.1kgf/cm2, 44.0 PSI)
Option 23.5-25-16PR
Rear Tire: 0.30 MPa (3.1kgf/cm2, 44.0 PSI)
NOTICE
The optimum inflation pressure differs according to the type of work. For details, see "HANDLING THE TIRES (PAGE 3-140)".
4 - 40
.

For the following items, see "CHECK BEFORE STARTING (PAGE 3-93)".
Check machine monitor
Check coolant level, add coolant
Check oil level in engine oil pan, add oil
Check fuel level, add fuel
Check electric wiring
Check parking brake
Check brake pedal
Check inflation pressure of tires
Check horn
4 - 41
.
DRAIN WATER, SEDIMENT FROM FUEL TANK

Loosen valve (1) on the right side of the tank so that the sediment
and water will be drained together with fuel.
4 - 42
.

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

(3 places)
1. By using a grease pump, pump in grease through the grease
fittings marked by the arrows.
2. After greasing, wipe off any old grease that was pushed out.
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until
they have cooled down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1. Lower the bucket horizontally to the ground and stop the

engine. Wait for 5 minutes, then check sight gauge (G). The
oil level should be between the H and L marks.
NOTICE
If the oil has been added to above H level, stop the engine and wait for the
hydraulic oil to cool down, then drain the excess oil from the drain plug. If
the oil is above H level, it will damage the hydraulic circuit or cause the oil
to spurt out.
2. If the oil is below the L level, open the inspection cover above the step and add oil through oil filler port (F).
4 - 43
.
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER

WARNING
If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as
protective glasses and mask.
If the air conditioner has been used, the air filter should be cleaned.
Stop the air conditioner before cleaning the element.
1. Push handle (1) and open cover (2).
2. Remove element (3) and clean it.

3. Direct dry compressed air (less than 0.69 MPa {7 kg/ 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 - 44
.

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

Perform this procedure before operating the machine.
WARNING
Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. This will accelerate deterioration of the inside
of the battery and reduce the service life of the battery. In addition, it may cause an explosion.
The battery generates flammable gas and there is danger of explosion, do not bring open flame or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
When adding distilled water to the battery, do not allow the battery electrolyte to go above UPPER LEVEL line. If the electrolyte
level is too high, it may leak and cause damage to the paint surface or corrode other parts.
Do not use a dry wipe to clean the battery. A wet wipe will prevent fire or explosion from static electricity.
NOTICE
If there is a fear that the battery water may freeze after refilling with purified water (e.g. commercially available replenishment water
for a battery), do the replenishment before the day's work on the next day.
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 UPPER
LEVEL (U.L.) and LOWER LEVEL (L.L.) lines.
3. If the electrolyte level is below the midway point between the

U.L and L.L lines, remove cap (1) and add distilled water to the
U.L line.
4. If distilled water has been added to any cell of cap (1), add
distilled water also to the other cells.
5. Clean the vents of the battery caps, then close the caps
securely.
Keep the top of the battery clean and wipe it with a wet cloth.
4 - 45
.
REMARK
If distilled water is added to above U.L. line, use a syringe to lower the level to U.L. line. Neutralize the removed fluid
with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu
distributor or battery maker.
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 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.
REMARK
If water is added to above the bottom tip of the sleeve, use a pipette to remove electrolyte. Neutralize the removed
electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your
Komatsu distributor or your battery maker.
WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL

If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
4 - 46
.
CHECK PARKING BRAKE

1. Set the machine on a dry downhill slope, press the parking
brake switch to the ON position, and check if the parking brake
hold the machine in position.
2. If any problem is found, contact your Komatsu distributor.
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST

CHECKING
The standard deflection between the air conditioner compressor
pulley and crank pulley when pressed with a thumb (approx. 98 N
{10 kg}) should be approx. 11 to 15 mm {0.4 to 0.6 in}.
When a belt tension gauge is used, the standard tension is within
a range of 353 to 530 N {36 to 54 kg}.
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 kg}) should be approx. 8 to 11.5 mm {0.315 to 0.5 in}.
When a belt tension gauge is used, the standard tension is within a range of 530 to 745 N {54 to 76 kg}.
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.
4 - 47
.
ADJUSTING
1. For adjustment, loosen bolt (1) and shift air compressor (2).
2. Tighten nut (1) to fix air compressor (2).
NOTICE
Check each pulley for damage, wear of the V-groove, and wear of the
V-belt. In particular, be sure to check that the V-belt is not touching the
bottom of the V-groove.
In case any of the following occurs, ask the Komatsu distributor in your
territory to replace the belts with new ones.
• The fan belt has elongated, leaving little allowance for adjustment.
• A cut or crack is found on the belt.
• Slipping or creaking sound is heard coming from the belt.
When the new V-belt is set, readjust it after 1 hour of operation.
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN

If wheel hub bolts (1) are loose, tire wear will be increased and
accidents may be caused.
1. Check for loose nuts, and tighten if necessary.
When checking for loose nuts, always turn the nuts in the
direction of tightening to check.
Tightening torque: 825 to 1030 Nm
(84 to 105 kgm, 607.6 to 759.9 lbft)
2. If any stud bolt is broken, replace all the stud bolts for that
wheel.
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER

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.
4 - 48
.

BRAKE ACCUMULATOR
If the engine stops when the machine is traveling, the oil pressure in the accumulator can be used to apply the brake
as an emergency measure.
1. Stop the machine on level ground and lower the work equipment completely to the ground.
2. Apply the parking brake.
3. Start the engine, run it at a mid-range speed for 1 minute, then stop the engine.
4. Turn the starting switch key to the ON position and depress the brake pedal repeatedly.
If the brake oil pressure caution lamp does not light up even when the brake is depressed 6 times, the gas
pressure in the accumulator is normal.
If the brake oil pressure caution lamp lights up when the brake has been depressed 5 or less times, the gas
pressure in the accumulator has probably dropped. Please contact your Komatsu distributor to have the
accumulator inspected.
REMARK
Carry out the check within 5 minutes after stopping the engine. If the machine is left with the engine stopped, the
accumulator pressure will drop and it will be impossible to check the cause of the problem.
4 - 49
.
LUBRICATING
1. By using a grease pump, pump in grease through the grease fittings marked by the arrows.
NOTICE
On jobsites where there is a lot of heavy-duty work, or on jobsites where operations are carried out continuously for more than
eight hours, reduce the greasing interval and carry out greasing more frequently.
(1) Bucket pin (2 places) (5) Lift arm pivot pin (2 places)
(2) Bucket link pin (2 places) (6) Bell crank pin (1 place)
(3) Dump cylinder pin (2 places) (7) Steering cylinder pin (4 places)
(4) Lift cylinder pin (4 places)
4 - 50
.

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
WARNING
Refill capacity: 32 liters (8.45 US gal)

Prepare a filter wrench
1. Open the engine side cover on the right side of the machine.
2. Open oil filler (F).
3. Place a container to catch the oil under drain plug (P).
4. Loosen drain plug (P), and drain the oil.
5. Check the drained oil, and if there are excessive metal
particles or foreign material, contact your Komatsu distributor.
6. Install drain plug (P).
7. Open the engine side cover on the left side of the chassis.
8. Using the filter wrench, turn filter cartridge (1)
counterclockwise to remove it.
In particular, if this operation is carried out immediately after
stopping the engine, a large amount of oil will come out, so wait
for 10 minutes before starting the operation.
9. Clean the filter holder, fill the new filter cartridge with engine oil,
then coat the seal and thread of the filter cartridge with engine
oil (or coat thinly with grease) and install.
10. When installing the seal, tighten it 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 idle 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 (PAGE 3-95)".
4 - 51
.
REPLACE FUEL FILTER CARTRIDGE

WARNING
The engine is at high temperature immediately after the machine has been operated. Wait for the engine to cool down before
replacing the filter.
Do not bring fire or sparks near the fuel.
1. Set the container to catch the fuel under the filter cartridge.
2. By using a filter wrench, turn filter cartridge (1)
counterclockwise on remove it.
3. Clean the filter head, fill the new filter cartridge with clean fuel,
coat the packing surface thinly with engine oil, and install it to
the filter holder.
Always use clean fuel when filling with fuel, and be careful not
to let any dirt or dust get in.
Add fuel from small hole (A) (dirty side) at eight places. Do not
add fuel from hole (B) (clean side) at the center.
4. When installing the seal, tighten it so its surface comes into
contact with the filter holder, then tighten another 3/4 turn.
If the filter cartridge is tightened too far, the packing will be
damaged and this will lead to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing, so
always tighten to the correct amount.
5. After replacing filter cartridge (1), loosen air bleed plug (2).
6. Bleed air with priming pump (3) and check that air bubbles
come out of air bleeding plug (2), followed by fuel.

8. After replacing the filter cartridge, start the engine and check that there is no leakage of fuel from the filter seal
surface. If there is any leakage of fuel, check the tightening of the filter cartridge. If there is still leakage of fuel,
follow Step 1 and 2 to remove the filter cartridge, then check the 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
3 - 8 to install the filter cartridge.
4 - 52
.

Maintenance for every 50, 100, 250 and 500 hours service should be carried out at the same time.
CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN
STRAINER
WARNING

1. Set a container to catch the oil under drain plug (P), then
remove drain plug (P) and drain the oil.
To prevent the oil from pouring out suddenly, loosen drain plug
(P) and remove it gradually.
2. After draining the oil, install drain plug (P).
Tightening torque: 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm, 50.6 ± 7.2
lbft}
3. Set a container to catch the oil under the transmission filter.
4. Remove drain plug (1) of the transmission filter, drain the oil,
then tighten the plug again.
5. Using a filter wrench, turn filter cartridge (2) to the left to remove
it.
6. Clean the filter holder, coat the seal surface and thread of the
new filter cartridge with clean oil, then install it.
7. When the seal surface comes into contact with the filter holder,
tighten a further 2/5 turns with the filter wrench.
8. Remove 4 bolts (3), move tube (4), then remove strainer (5).
9. Remove any dirt stuck to strainer (5), then wash it in clean
diesel fuel or flushing oil. If strainer (5) is damaged, replace it
with a new part.
10. Install strainer (5) in the case.
Replace the O-ring of tube (4) with a new part, then install tube
(4).
4 - 53
.
11. Refill the specified quantity of oil through oil filler (F).
12. After filling with oil, check that the oil is at the specified level.
For details, see "CHECK TRANSMISSION OIL LEVEL, ADD
OIL (PAGE 4-25)".
13. Check that there is no leakage of oil from the transmission
case or oil filter.
CLEAN TRANSMISSION CASE BREATHER

1. Open cover (1) on the cab side of the engine hood.
2. Remove the mud and dirt from around the breather, then
remove breather (2), soak it in washing liquid and wash it.
After removing the breather, take steps to prevent dirt or dust
from entering the mount.
LUBRICATING
(1) Center hinge pin (2 places)
(2) Drive shaft center support (1 place)
4 - 54
.
CHECK TIGHTENING PARTS OF TURBOCHARGER

Ask your Komatsu distributor to have the tightening portions checked.
CHECK PLAY OF TURBOCHARGER ROTOR

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

Since inspection and replacement of the fan belt requires special tools, contact your Komatsu distributor.
REMARK
The machine is equipped with an auto tensioner, so there is no need to adjust the tension.
If the alternator drive belt is in the following condition, the belt must
be replaced. Please ask your Komatsu distributor to replace the
belt.
When horizontal scratch (1) crosses vertical scratch (2)
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.
REPLACE CORROSION RESISTOR CARTRIDGE

1. Close a valve (1) of the corrosion resistor at two points.
2. Using a filter wrench, turn cartridge (2) to the left to remove it.
3. Apply engine oil to the sealing surface of a new cartridge, then
install it to the filter holder.
4. Bring the packing surface into contact with the seal surface of
the filter holder, then tighten it further approx. 2/3 turn.
5. Open a valve (1) of the corrosion resistor at two points.
4 - 55
.

Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time.
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT

WARNING
1. Lower the bucket horizontally to the ground and apply the parking brake, then stop the engine.
2. Remove bolts (1), then remove cover (2).
3. Remove oil filler cap (F).
4. Set a container to catch the oil under drain plug (3).

5. Remove drain plug (3).
6. Open drain valve (4) gradually and drain the oil.
7. After draining the oil, close drain valve (4), then tighten drain
plug (3).
Tightening torque
Drain plug (3): 68.6 ± 9.8 Nm (7.0 ± 1.0 kgm, 50.6 ± 7.2 lbft)
Drain valve (4): 63.7 ± 14.7 Nm (6.5 ± 1.5 kgm, 47.0 ± 10.8 lbft)
4 - 56
.
8. Remove mounting bolts (6) of filter cover (5) at the top of the
tank, then remove the cover.
When the cover is removed, the force of spring (7) may make
the cover fly off, so keep the cover pushed down when
removing the bolts.
9. Remove spring (7) and bypass valve (8), then remove element
(9).
10. Check that there is no foreign material inside the tank, then
clean it.
11. Install new element (9), then set bypass valve (8), spring (7),
and cover (5) to the tank.
If the O-ring of the cover is damaged or deteriorated, replace it.
12. When installing the cover bolts, push down the cover and
tighten the bolts evenly.
13. Add the refill amount of engine oil through oil filler port (F), then
install the cap.
14. Check that the hydraulic oil is at the standard level. For details,
see "CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
(PAGE 4-43)".
15. Run the engine at low idle, 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 approximately 100 mm (3.9 in) before the end of
stroke).
NOTICE
If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder
may cause damage to the piston packing.
16. Next, operate the steering, bucket, and lift arm cylinders to the
end of their stroke 3 to 4 times, then stop the engine and loosen
bleed plug (10) to bleed the air from the hydraulic tank. After
bleeding the air, tighten plug (10) again.
Run the engine at low idle when bleeding the air.
17. Check that the hydraulic oil is at the standard level. For details,
see "CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
(PAGE 4-43)".
18. Next, increase the engine speed and repeat the procedure in Step 16 to bleed the air. Continue this operation
until no more air comes out from plug (10).
19. After completing the air bleed operation, tighten plug (10).
20. Check that the hydraulic oil is at the standard level. For details, see "CHECK OIL LEVEL IN HYDRAULIC TANK,
21. Check that there is no leakage of oil from the filter cover mount.
4 - 57
.
REPLACE HYDRAULIC TANK BREATHER ELEMENT

WARNING
1. Before removing the breather, wipe off all the dirt from around
the breather.
2. Remove the cap of oil filler (F).
3. Remove nut (2) of breather (1), then remove cover (3).
4. Replace filter element (4) with a new part, then install cover (3)
and nut (2).
5. Tighten the cap of oil filler (F).
REMARK
It is possible to replace the element with the breather installed in
the tank. However, if the breather is removed, do not wrap the
taper thread of the breather with seal tape when assembling again,
and be careful not to tighten too much.
4 - 58
.
CHANGE AXLE OIL

WARNING
When changing the oil, apply the parking brake and secure the front and rear frames with the frame lock bar.
After the engine is stopped, the parts and oil are at high temperature, and may cause burns. Wait for the temperature to go
down before starting the operation.
When the plug is removed, oil may spurt out, so turn it slowly to release the internal pressure, then remove it carefully.
Refill capacity (front and rear, each): 38 liters (10.04 US gal)
1. Set a container to catch the oil under drain plug (P).

2. Remove front and rear oil filler plugs (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 specified level.
REMARK
For axles with ASD (Limited-Slip Differential), the brand of
lubricating oil is different. Use the specified lubricating oil.
5. After adding oil, check at level plug (1) that the oil is at the
specified level. For details, see "CHECK AXLE OIL LEVEL,
REMARK
For operations where the brake is used frequently, change the axle oil at shorter intervals.
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER

Remove both the recirculation air filter and fresh air filter in the same way as when cleaning, and replace them with
new parts.
For details of cleaning the recirculation air filter, see "CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION
FILTER (PAGE 4-48)".
For details of cleaning the fresh air filter, see "CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER
(PAGE 4-44)".
4 - 59
.
CLEAN PPC CIRCUIT STRAINER

WARNING
After the engine is stopped, the parts and oil are at high temperature, and may cause burns. Wait for the temperature to go
down before starting the operation.
When the rubber hose is removed, oil may spurt out, so turn it slowly to release the internal pressure, then remove it carefully.
1. Remove a cover under the floor frame at the left side of

machine.
2. When rubber hose (1) and flange (2) are removed, oil will spill
out, so set a container (capacity: approx. 300 cc) in position to
catch the oil.
3. Remove rubber hose (1) and flange (2).
4. Remove strainer (3) and wash it in clean diesel oil.
5. Assemble strainer (3) in strainer case (4) with the strainer
protrusion side (O-ring side) facing the front and fix it with
flange (2).
6. Install rubber hose (1).
7. Install the cover.
CLEAN ENGINE BREATHER ELEMENT

WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait untill
When using compressed air, there is a hazard that dirt may be blown up and cause serious injury.
Always use protective eyeglasses, dust mask, or other protective equipment.
1. Wipe away dust around the breather.

2. Loosen the clamp and remove the hose. Remove breather (1).
3. Clean the breather body with light oil or cleaning oil.
4. Replace O-ring with new one. Coat a new O-ring with engine
oil, set it, then install breather (1).
5. Check the breather hose and pipe. If caked oil (sludge) adhere
to insides, replace the hose and pipe with new parts.
4 - 60
.
CHECK BRAKE DISC WEAR

WARNING
When checking the brake disc wear, apply the parking brake and secure the front and rear frames with the frame lock bar.
Make sure that the brake oil temperature is less than 60°C (140°F) before checking the brake wear.
If the disc is near the wear limit, carry out inspection at shorter intervals, regardless of the specified inspection interval.
When checking the brake disc for wear, there are 4 places (front axle and rear axle, left and right), so use the same
procedure to check all 4 places.
1. Remove cap nut (1).
2. Depress the brake pedal, keep it depressed, and push in the

rod (2) of the gauge until contacts the piston.
3. The wear is the amount that the end face of rod (2) is protruding
from the end face of guide (3). Measure the amount of
protrusion.
The point where the rod groove is level with the end face of the
guide is the permissible limit for the disc wear.
If the wear has reached this point, please ask your Komatsu
distributor for inspection and replacement parts.
If the disc is near the wear limit, carry out inspection at
shorter intervals, regardless of the specified inspection
interval.
4. Install cap nut (1).
Tightening torque: 29.4 to 39.2 Nm {3.0 to 4.0 kgm, 21.7 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).
4 - 61
.

PPC ACCUMULATOR
If the engine stops with the work equipment raised, and it is impossible to start the engine again, it is possible as an
emergency measure to actuate the valve with the oil pressure stored in the accumulator and lower the work
equipment to the ground.
1. Apply the parking brake.
2. Raise the work equipment to the maximum height, then
operate the lift arm control lever to HOLD position (b).
3. Stop the engine.
4. Leave the work equipment lock lever in the FREE position.
5. Check that the area around the machine is safe, then operate
the lift arm control lever to FLOAT position (d) and lower the
work equipment to a point 1m above the ground.
6. When the lift arm comes to the 1m position, return the lift arm
control lever to LOWER position (c), and lower the work
equipment slowly to the ground.
REMARK
Carry out the check within 2 minutes after stopping the engine. If
the machine is left with the engine stopped, the accumulator
pressure will drop and it will be impossible to check the cause of the
problem.
If the work equipment stops while it is moving, the gas pressure in the accumulator has probably dropped.
Replace the accumulator every 4000 hours or every 2 years.
CHECK ALTERNATOR, STARTING MOTOR

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

As special tool is required for removing and adjusting the parts, request your Komatsu distributor for service.
CLEAN AND CHECK TURBOCHARGER

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 INJECTOR
Check the exhaust gas color visually. If there is any problem in the exhaust gas color, please contact your Komatsu
distributor for inspection or replacement. For details of the action to take if there is a problem, see "ENGINE (PAGE
3-165)".
4 - 62
.
CHECK VIBRATION DAMPER

Check that there are no cracks or peeling in the outside surface of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.
4 - 63
.

Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours service should be carried out at the same time.
LUBRICATING
Carry out the greasing once every 2 years, regardless of whether the 4000 hour interval has passed.
1. Set the grease fitting marked by arrows on the front drive shaft facing down.
(1) Center drive shaft spline (1 place)
(2) Front drive shaft (2 places)
(3) Rear drive shaft (2 places)
(4) Center drive shaft (2 places)
4 - 64
.
CHECK WATER PUMP

Check that there is no play in the pulley or any grease leakage, water leakage, or clogging of the drain hole. If any
problem is found, contact your Komatsu distributor for disassembly and repair or replacement.
CHECK AIR CONDITIONER COMPRESSOR, ADJUST

As special tool is required for checking and adjusting the parts, request Komatsu distributor for service.
REPLACE INJECTOR ASSEMBLY

Ask your Komatsu distributor to perform this work.
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER
Check visually and touch with your fingers to check that there are no loose bolts or hardening of rubber parts at
clamps (1) to (4). If there is any looseness or hardened rubber, contact your Komatsu distributor for replacement.
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
Check if any of fuel spray prevention caps (1) through (12) is missing, or if any part of the rubber is hardened. If either
of the cases is found, call your Komatsu distributor for the installation or replacement.
4 - 65
.

Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time.
REPLACE HIGH-PRESSURE PIPING CLAMP

REPLACE FUEL SPRAY PREVENTION CAP

4 - 66
.
5-1
.
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
WA380-5 standard specification machine
Item Unit
(when using POWER mode)
Operating weight (including 1 operator: 75 kg
kg (lb) 16,230 (35787)
(165 lb) (With bolt on cutting edge)
Normal load kg (lb) 5,280 (11642)
Bucket capacity Heaped m3 (cu.yd) 3.3 (4.3)
Engine model - Komatsu SAA6D114E-2 diesel engine
Flywheel horsepower kW (HP)/rpm 140 (187)/2,000
A Overall length mm (ft in) 8,235 (27')
B Overall height mm (ft in) 3,315 (10' 11")
C Max. dimension when shaking bucket mm (ft in) 5,565 (18' 3")
D Overall width mm (ft in) 2,695 (8' 10")
E Min. ground clearance mm (ft in) 390 (1' 3")
F Bucket width mm (ft in) 2,905 (9' 6")
G Clearance Cutting edge [BOC tip] mm (ft in) 2,885 (9' 6") [2,800 (9' 2")]
H Reach Cutting edge [BOC tip] mm (ft in) 1,165 (3' 10") [1,210 (4')]
I Dump angle degrees 45
Min. turning radius Out of chassis mm (ft in) 6,540 (21' 5") [6,580 (21' 7")]
Center of outside tire mm (ft in) 5,620 (18' 5")
Permissible towing load kg(N) 12,180(119,440)
1st km/h (MPH) 6.3 (3.9)
2nd km/h (MPH) 11.4 (7.1)
Forward
3rd km/h (MPH) 20.2 (12.6)
4th km/h (MPH) 31.5 (19.6)
Travel speed
1st km/h (MPH) 6.7 (4.2)
2nd km/h (MPH) 11.8 (7.3)
Reverse
3rd km/h (MPH) 21.0 (13.0)
4th km/h (MPH) 32.5 (20.2)
5-2
.
6-1
.
SELECTING BUCKET AND TIRES ATTACHMENTS, OPTIONS
SELECTING BUCKET AND TIRES

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

Loading products Stockpile bucket General ground
(with bolt-on cutting edge) 23.5-25-16PR (L3 Rock)
conditions
Loading and (3.3 m3 (4.3 cu.yd)
carrying products Stockpile bucket (with teeth)
Leveled ground 23.5-25-12PR (L2 Traction)
(3.1 m3(4.1 cu.yd)
Light material bucket
(with bolt-on cutting edge) Soft ground 23.5-25-12PR (L2 Traction)
(3.8 m3(5.0 cu.yd)
Loading crushed Excavating bucket General ground
23.5-25-20PR (L3 Rock)
rock (with segment edge) conditions
(2.7 m3 (3.5 cu.yd) 20.5-25-16PR (L3 Rock)
Soft ground
23.5-25-16PR (L3 Rock)
Ground with many 23.5-25-12PR (L3 Rock)
light rocks (Side steel breaker)
Soft ground with 23.5-25-12PR (L3 Rock)
many light rocks (Side steel breaker)
BOC indicates a bolt-on type cutting edge.
The displayed travel speed changes according to the tire size, so when installing optional tires, please contact your
6-2
.
ATTACHMENTS, OPTIONS HANDLING LOAD METER
HANDLING LOAD METER

GENERAL LOCATIONS
MACHINE MONITOR WITH LOAD METER
(1) Load meter display (2) Character display
The only difference from the machine monitor described in EXPLANATION OF COMPONENTS in the
OPERATION section is that the load meter panel is installed in place of the speedometer and meter display pilot
lamp.
For details of items not given here, see "MACHINE MONITOR (PAGE 3-6)" in the OPERATION section.
6-3
.
HANDLING LOAD METER ATTACHMENTS, OPTIONS
SWITCHES
(1) Load meter cancel switch (3) Monitor panel mode selector switch 1
(2) Load meter sub total switch (4) Monitor panel mode selector switch 2
For details of switches (3) and (4), see "MONITOR PANEL MODE SELECTOR SWITCH 1 (PAGE 3-42)" and
"MONITOR PANEL MODE SELECTOR SWITCH 2 (PAGE 3-43)".
LOAD METER CANCEL SWITCH

If it is not necessary to keep the measurement data, press switch
(1) at the top of the bucket control lever.
The data that has just been added is canceled and the display
returns to the value before measurement.
LOAD METER SUB TOTAL SWITCH

To return the aggregate load display (in addition mode) or the
remaining load display (in subtraction mode) to 0, press switch (2)
at the side of the bucket control lever.
6-4
.
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)
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.
Addition mode (measuring total amount loaded)

This method is useful for measuring the production, such as the amount loaded into the dump truck, the amount
loaded into the hopper, or the total work for half a day. The data can be displayed up to a maximum of 9999 tons
for each type of work.
Remain method (measuring amount remaining)
Use this method for work requiring a determined amount (prevention of overloading, mixing of different types of
material, etc.)
REMARK
The total load display or remaining load display (3) can be displayed up to a maximum of 999.9 tons when displaying
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.
6-5
.
LOAD METER ADDITION MODE

For details of the method of switching to the addition mode, see
"SETTING ADDITION MODE (PAGE 6-9)".
"TOTAL LOADED" lights up on load meter display (1).
The bucket load is displayed on load meter display (2), and the
total load is displayed on display (3).
If the measured data is not needed, press load meter cancel

switch (4).
The data for the last calculation is canceled and display (3)
returns to the display for the previous measurement.
To return total load display (3) to 0, press load meter sub total
switch (5).
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

For details of the method of switching to the remain mode, see
"SETTING REMAIN MODE (PAGE 6-11)".
"REMAINING TARGET" lights up on load meter display (1).
The bucket load is displayed on load meter display (2), and the
amount remaining to the target is displayed on display (3).
If the measured data is not needed, press load meter cancel

switch (4).
The data for the last calculation is canceled and display (3)
returns to the display for the previous measurement.
To return total load display (3) to 0, press load meter sub total
switch (5).
6-6
.
SELECTION OF DISPLAY FOR TYPE OF LOAD

For details of the method of selecting the type of load, see
"SETTING ADDITION MODE (PAGE 6-9)" and "SETTING
REMAIN MODE (PAGE 6-11)".
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 REMAINING
TARGET for each type of material.
One of the selected types of material A to E is displayed on load
meter display (1).
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY

CALIBRATION
1. Necessity
The pressure when unloaded and loaded (rated load, 1/2 rated load) <-> load map is registered in the machine
monitor panel. However, there are variations in each machine, and variations when the bucket is repaired, so
it is necessary to calibrate the map to compensate for the variations in each machine in order to ensure the
accuracy of the load meter. For this reason, there is a calibration system. Calibration must be carried out in the
following cases.
When new machine is delivered
When lift arm is changed
When machine monitor panel is replaced
When the pressure sensor, lift arm angle sensor is replaced
Periodically (every 3 months)
2. Points to remember when carrying out calibration

When carrying out calibration, remember the following points.
When calibrating the load, it is necessary to use a known weight, or to calculate the weight of the machine
using a load meter when the machine is loaded with the target material and when it is unloaded.
Payload: Put the following weight or target material into the bucket and carry out calibration.
Unloaded calibration EMPTY BUCKET

1/2 rated load calibration 1.9 - 3.2 ton
Rated load calibration 4.5 - 5.7 ton
Note: If the load is far outside the range, it will be impossible to calibrate
the map and the accuracy will deteriorate.
Load the posture: Carry out the load calibration in the same posture as when carrying out actual operations.
Warming up: Carry out warming up to set the hydraulic oil temperature to the normal working range, then
carry out normal operations (including raising and lowering the lift arm) for at least 10 minutes
(preferably more than 30 minutes).
Lift arm RAISE speed: To make the lift arm RAISE speed constant, carry out at the lift arm RAISE detent.
Accelerator pedal: Depress the accelerator pedal to the same angle as for actual operations. Do not change
the angle of the accelerator pedal. Always keep it constant.
Bucket posture: Measure at full tilt. Carry out calibration also at full tilt.
For details of the method of calibration, see "CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN
EMPTY (PAGE 6-17)", "CALIBRATING WITH 1/2 RATED LOAD (PAGE 6-19)" and "CALIBRATING WITH
RATED LOAD (PAGE 6-22)".
6-7
.
DELETING LOAD METER DISPLAY

It is possible to set so that there is no load meter display.
If there is no display, only the speed is displayed.
To switch the load meter between display and no display, see "STOPPING CALCULATION (PAGE 6-16)".
SPEED DISPLAY
The travel speed of the machine is displayed on load meter
display (1).
It is also possible to switch this display (1) so that it displays the

engine speed.
If you wish to switch the speed display to the engine speed display,
please ask your Komatsu distributor to carry out the operation.
6-8
.
HANDLING LOAD METER DISPLAY
SETTING ADDITION MODE

When carrying out loading operations in the addition mode, refer to "ADDITION FUNCTION (PAGE 6-25)" after
setting the addition mode.
1. Check that the normal service meter and time are displayed on
the character display.
2. Press the () of monitor panel selector switch 1 and display

"LOAD METER".

"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.
6-9
.
4. If the display is "REMAINS MODE", press the (>) or (<) of

monitor panel mode selector switch 2 to display "ADDITION
MODE".

"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
displayed 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 monitor
panel mode selector switch 2 to select the type of material,
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 - 10
.
SETTING REMAIN MODE

When carrying out operations in the remain mode, set to the remain mode. For details of the remain mode functions,
see "SUBTRACTION FUNCTION (PAGE 6-27)".

"LOAD METER".

"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 - 11
.
4. If the display is "ADDITION MODE", press the (>) or (<) of

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

"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.
"INPUT TARGET".
9. Input the target load.
Before the target is input, "0000.0 t" is displayed on the target
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 selector
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 selector
switch 1.
6 - 12
.
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 selector switch 1.
13. "0" is already displayed at both the 1 ton and 0.1 ton positions,
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 - 13
.
TOTAL LOAD DATA DISPLAY


"LOAD METER".
3. Press the () of monitor panel selector switch 1, then press

the (>) or (<) of monitor panel mode selector switch 2 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.
select the data for each of A to E or the all lighted-up display.
6 - 14
.
The total load data for each of A to E and for all data is displayed
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 displayed.
The total value can be cleared as follows.

1) Press the (>) or (<) of monitor panel mode selector switch
2, and select the individual items to be cleared from A to E
or select the all lighted-up display.
2) Press the () of monitor panel selector switch 1 to display
"RESET".
3) "YES < > NO" is displayed, and the cursor is at the NO
position, so press the(<) of monitor panel mode selector
switch 2 to move the cursor to the "Y" of YES.
4) Press the () of monitor panel mode selector switch 1.

The selected individual item from A to E or all the data is
cleared.
If the monitor accepts the clear command, the buzzer gives
short sounds and the display returns to the normal service
meter and time display.
6 - 15
.
STOPPING CALCULATION

"LOAD METER".

the (>) or (<) of monitor panel mode selector switch 2 and
select "OFF" on the bottom line.
4. Press the () of monitor panel selector switch 1. The load

meter display goes out and the screen switches to the speed
display. In addition, the character display returns to the normal
service meter and time display.
5. When starting the calculation again, set to the addition mode or
remain mode. For details, see "SETTING ADDITION MODE
(PAGE 6-9)" or "SETTING REMAIN MODE (PAGE 6-11)".
6 - 16
.
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 to 85°C (140 to 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
operations (near the rated speed).
(The effect of compensation for the engine speed shows the maximum effect. When carrying out the actual
measurement, 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
seconds 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.)

"LOAD METER".

the (>) or (<) of monitor panel mode selector switch 2 and
select "CALIBRATION".
6 - 17
.
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 display

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

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

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 - 18
.
CARRYING OUT CALIBRATION WHEN LOADED
CALIBRATING WITH 1/2 RATED LOAD

1. Before carrying out calibration, set the machine in the following condition.
1) Carry out the warming-up operation.
Carry out warming up to set the hydraulic oil temperature to the normal working range, then carry out normal
operations (including raising and lowering the lift arm) for at least 10 minutes (preferably more than 30
minutes).
2) Load the bucket with a known weight. (For this machine: 1.9 - 3.2 tons)
Be careful that the center of gravity of the load does not change when raising or lowering the lift arm.
2. Set so that the character display shows the normal service
meter and clock display.
3. Press the () of monitor panel mode selector switch 1 and

display "LOAD METER".
4. Use the () portion of the monitor panel mode selector switch
1 and the (>) or (<) portion of the monitor panel mode selector
switch 2 to display "CALIBRATION" on the character display.
6 - 19
.
5. Press the () portion of the monitor panel mode selector

switch 1.
"CALIBRATION EMPTY BUCKET" is displayed on the
character display.
6. Press (>) of monitor panel mode selector switch 2. Character

display shows "calibration".

switch 1.
"STEP 1" is displayed on the top line of the character display,
and "FULLY ROLL BACK" and "AT CARRY POSI" are
displayed in turn for 3 seconds each on the bottom line.
8. Tilt the bucket back fully, then lower the lift arm to set to the
travel posture.
When the lift arm is lowered, the display on the character
display changes to "STEP 2 RAISE TO TOP".
9. Raise the lift arm to the maximum height at the same speed as
for actual operations.
Depress the accelerator pedal to the same angle as for actual
operations. Keep the accelerator angle constant and do not
change it. Carry out the lift arm RAISE at the detent.
6 - 20
.
10. When the calibration is completed correctly, the screen for

inputting the weight is displayed.
REMARK
The () portion of monitor panel selector switch 1 is used to accept
the display on the character display. When the switch is pressed,
the input for the digit marked by the cursor is accepted and the
cursor moves to the next digit. Use the (>) or (<) portion of monitor
panel selector switch 2 to changethe input value. Press the (>)
portion to increase the value; press the (<) to decrease the value.
After using the (>) or (<) portion of monitor panel selector switch 2
to change the input value, press the () portion of monitor panel
selector switch 1 to accept the input value for the digit marked by
the cursor.
The load meter automatically judges if it is "1/2 rated load
calibration" or "rated load calibration", and rewrites the data. Even
if the input value is the same as the previous value, input the
weight.
When the weight is input, the buzzer sounds and the character
display returns to the normal service meter and clock display.
If the calibration when loaded cannot be completed normally, the

buzzer sounds, "CALIBRATION" appears on the top line of the
character display, and "LOAD BUCKET" appears on the bottom
line.
11. If the calibration when loaded cannot be completed normally,

carry out the operation again from Step 6.
6 - 21
.
CALIBRATING WITH RATED LOAD
1. Before carrying out calibration, set the machine in the following condition.
1) Carry out the warming-up operation.
Carry out warming up to set the hydraulic oil temperature to the normal working range, then carry out normal
operations (including raising and lowering the lift arm) for at least 10 minutes (preferably more than 30
minutes).
2) Load the bucket with a known weight. (For this machine: 4.5 - 5.7 tons)
Be careful that the center of gravity of the load does not change when raising or lowering the lift arm.
2. Set so that the character display shows the normal service
meter and clock display.

4. Use the () portion of the monitor panel mode selector switch
1 and the (>) or (<) portion of the monitor panel mode selector
switch 2 to display "CALIBRATION" on the character display.

switch 1.
"CALIBRATION EMPTY BUCKET" is displayed on the
character display.
6 - 22
.
6. Press (>) of monitor panel mode selector switch 2. Character

display shows "calibration".

switch 1.
"STEP 1" is displayed on the top line of the character display,
and "FULLY ROLL BACK" and "AT CARRY POSI" are
displayed in turn for 3 seconds each on the bottom line.
8. Tilt the bucket back fully, then lower the lift arm to set to the
travel posture.
When the lift arm is lowered, the display on the character
display changes to "STEP 2 RAISE TO TOP".
9. Raise the lift arm to the maximum height at the same speed as
for actual operations.
Depress the accelerator pedal to the same angle as for actual
operations. Keep the accelerator angle constant and do not
change it. Carry out the lift arm RAISE at the detent.
10. When the calibration is completed correctly, the screen for
inputting the weight is displayed.
REMARK
The () portion of monitor panel selector switch 1 is used to accept
the display on the character display. When the switch is pressed,
the input for the digit marked by the cursor is accepted and the
cursor moves to the next digit. Use the (>) or (<) portion of monitor
panel selector switch 2 to changethe input value. Press the (>)
portion to increase the value; press the (<) to decrease the value.
After using the (>) or (<) portion of monitor panel selector switch 2
to change the input value, press the () portion of monitor panel
selector switch 1 to accept the input value for the digit marked by
the cursor.
The load meter automatically judges if it is "1/2 rated load
calibration" or "rated load calibration", and rewrites the data. Even
if the input value is the same as the previous value, input the
weight.
6 - 23
.
When the weight is input, the buzzer sounds and the character
display returns to the normal service meter and clock display.
If the calibration when loaded cannot be completed normally, the

buzzer sounds, "CALIBRATION" appears on the top line of the
character display, and "LOAD BUCKET" appears on the bottom
line.
11. If the calibration when loaded cannot be completed normally,

carry out the operation again from Step 6.
RESETTING CALIBRATION
1. Check that the standard service meter and time is displayed on

3. Press monitor panel mode selector switch 1 (), then press

monitor panel mode selector switch 2 (>) or (<) to display
"CALIBRATION RESET" on the character display.
4. Press monitor panel mode selector switch 1 (), press monitor
panel mode selector switch 2 (<) to move the cursor to "YES",
then press monitor panel mode selector switch 1 ().
6 - 24
.
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

The suitable precision for the weight of the bucket load can
be obtained if the engine speed is slightly above low idling.
Set the bucket to the full tilt position.
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 measurement,

the bucket load is canceled and the display returns to 0.0.
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.
6 - 25
.
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 measurement,

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.
7. The screen will return to the initial display.
6 - 26
.
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.
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 carried 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.
6 - 27
.
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
displayed.
5. The target load is displayed as -3.0 tons, and after 3 seconds,

the display changes to the display shown on the right.
The target value of 2.0 tons is the target load after completing
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.
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 character
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.
6 - 28
.
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 operation,
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.
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.
6 - 29
.
METHOD OF SETTING TIME ON CLOCK

(The time display is only available on machines equipped with the load meter)

"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".

The top line displays "ADJUST 23: 59".
The bottom line displays "2000/01/01".
REMARK
Once the time is input, the clock will show the correct time from that
time on.
5. Input the day and time.

The cursor is displayed at each input item in the following order: Year, Month, Day, Hour, Minute.
Use the (>) or (<) of monitor panel mode selector switch 2 to move the numbers up or down and input numbers
between 0 and 9 at the cursor position.
6. After inputting the number, press the () of monitor panel mode selector switch 1 to select and move the cursor
to the next input position.
Repeat Steps 5 and 6 to input and select the numbers from the year to the minute.
6 - 30
.
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 display.
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 - 31
.
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 (PAGE 6-33)".
A mode: Printout of totals

The number of loads and total amount loaded for each type of material are printed out.
B mode: Printout of subtotals
The total for each load, number of loads, and total amount loaded for each type of material are printed out.
C mode: Printout of operating record
In addition to the items printed out in A mode, the maintenance items and time remaining until maintenance
are also printed out.
The printouts shown below are examples of the load meter printouts for the WA470.
6 - 32
.
METHOD OF SELECTING PRINTOUT MODE

(This functions only when the optional printer is installed.)

"LOAD METER".
3. Press the () of monitor panel mode selector switch 1, then

press the (>) or (<) of monitor panel mode selector switch 2 to
select "PRINT TYPE".

The bottom line will change to display the printout mode "A < >
B < > C".
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 (PAGE 6-32)".
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 - 33
.
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 - 34
.
ATTACHMENTS, OPTIONS HANDLING TORQUE CONVERTER LOCK-UP
HANDLING TORQUE CONVERTER LOCK-UP

WARNING
When traveling down slopes of a grade of more than 6°, never depress the accelerator pedal fully, regardless of whether the torque
converter lockup switch is ON or OFF. It is extremely dangerous to drive too fast.
NOTICE
To prevent overrunning when traveling at high speed in the following cases, do not shift down gear.
When traveling in F3 at a speed of more than 25 km/h (15.5 MPH), do not shift down to F2.
When traveling in F4 at a speed of more than 36 km/h (22.4 MPH), do not shift down to F3.
When the actual speed range is 3rd or 4th in either FORWARD or REVERSE, the torque converter lock-up function
is actuated according to the travel speed and sets to direct drive.
To prevent overrun, the lock-up is automatically canceled to prevent the travel speed from going above 40 km/h
(24.9 MPH).
GENERAL LOCATIONS
(1) Torque converter lock-up switch (3) Shift indicator (displays actual speed range)
(2) Torque converter lock-up pilot lamp (4) Character display
TORQUE CONVERTER LOCK-UP SWITCH

This switch (1) is the control switch for the torque converter lock-up
function.
Position (a): ON
The pilot lamp inside the switch lights up and the
lock-up is actuated according to the travel speed.
While the lock-up is engaged, the lock-up pilot lamp
on the machine monitor lights up.
Position (b): OFF
The lock-up does not function.
6 - 35
.
HANDLING TORQUE CONVERTER LOCK-UP ATTACHMENTS, OPTIONS
TORQUE CONVERTER LOCK-UP PILOT LAMP

This monitor (2) lights up when the torque converter lock-up is
engaged and the transmission actually enters direct drive.
For details of (3) and (4), see "SHIFT INDICATOR (PAGE 3-27)" and "ACTION CODE DISPLAY (PAGE 3-9)" in the
section on the machine monitor in the OPERATION section.
METHOD OF OPERATION
1. Press the top (a) of the torque converter lock-up switch to turn
it ON.
The pilot lamp inside the switch lights up.
2. When the actual speed range is 3rd or 4th in either FORWARD
or REVERSE, the torque converter lock-up function is
actuated according to the travel speed and sets to direct drive.
REMARK
When the gearshift lever is at 4th in auto-shift mode, the lock-up is
not actuated if the actual speed range is 3rd. The lock-up is
actuated only when the actual speed range is 4th.
When the lock-up is actually actuated, the lock-up pilot lamp on the
machine monitor lights up.
3. To cancel the lock-up, press the bottom (b) of the torque

converter lock-up switch to turn it OFF.
The lock-up is canceled.
The travel speed for actuation and cancellation of the lock-up is as shown below.
Lock-up FORWARD travel speed REVERSE travel speed

(km/h (MPH)) (km/h (MPH))
Speed range Actuated Canceled Actuated Canceled
11 to 14 10 to 12 16 13
3rd
(6.8 to 8.7) (6.2 to 7.5) (9.9) (8.1)
21 to 24 19 22 to 25 20
4th
(13.0 to 14.9) (11.8) (13.7 to 15.5) (12.4)
6 - 36
.
ATTACHMENTS, OPTIONS HANDLING TORQUE CONVERTER LOCK-UP
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED

TRAVEL SPEED WARNING FUNCTION
(This functions even when the torque converter lock-up switch is OFF.)
When the travel speed goes above 38.0 km/h (23.6 MPH), the central warning lamp lights up and the alarm buzzer
sounds.
At the same time, "E00 OVERRUN PROTECT" is displayed on the character display.
If the alarm buzzer sounds, depress the brake immediately to slow the machine down.
When the travel speed goes below 36.0 km/h (22.4 MPH), the alarm buzzer stops.
TRAVEL SPEED LIMIT FUNCTION

(This functions only when the torque converter lock-up switch is ON.)
To prevent the travel speed from going above 40.0 km/h (24.9 MPH), the lock-up is automatically canceled.
The lock-up cancel continues until the travel speed goes below 38.0 km/h (23.6 MPH).
6 - 37
.
HANDLING AUTO-GREASING SYSTEM ATTACHMENTS, OPTIONS
HANDLING AUTO-GREASING SYSTEM

With this system, the grease is automatically supplied through the computer controls.
If any abnormality occurs in the lubrication controller, please inform your Komatsu distributor of the symptoms and
ask for repairs to be carried out.
METHOD OF OPERATING AUTO-GREASING SYSTEM

REMARK
Immediately after the power is turned on, all the display lamps on
the lubrication controller inside the box under the step on the left
side of the machine light up for several seconds. This is a self
check for the lamps,and does not indicate any abnormality.
The display portion for starting the calculation of the greasing
interval will flash, but all other displays will go out after a few
seconds.
However, even if the greasing interval has not been reached, if the
switch is turned ON/OFF repeatedly, greasing will automatically
start due to the function of the supplemental circuit, immediately
after the starting switch is turned ON. After display of the
7-segment LED and greasing-in-progress LED, as shown in the
"LUBRICATION CONTROLLER DISPLAY TABLE", the above
condition will be returned.
2. Centralized greasing is carried out in accordance with the set time and frequency limit for greasing.
REMARK
If the starting switch is turned ON/OFF frequently before the greasing interval is reached, the warning for the
remaining time is displayed earlier, but this does not indicate any abnormality.
6 - 38
.
ATTACHMENTS, OPTIONS HANDLING AUTO-GREASING SYSTEM
LUBRICATION CONTROLLER DISPLAY TABLE
(1) 7-segment LED (6) Greasing LED

(2) Cancel key (7) Warning LED
(3) Level selector key (8) Setting LED
(4) Blade-type fuse (9) Starting key
(5) Power source LED (10) Item selector key
Remaining number of times of greasing

If the remaining number of times of greasing is less than 10,
remaining number is displayed and it flashes. If the remaining
number of times is 10 or more, only the flashing is shown without
displaying the number.
OPERATION AS DESIRED
If auto-greasing switch (1) on the right switch panel or the start
button of the lubrication controller inside the box under the step on
the left side of the machine are pressed, one cycle of greasing will
be carried out regardless of the hours of operation.
The time count for the greasing interval will be canceled, and when
the electric pump automatically stops, the count will start again.
6 - 39
.
PILOT LAMP DISPLAY ON MACHINE MONITOR
The display of pilot lamp (2) on the machine monitor lights up or

flashes according to the following conditions.
Lighted up: Normal operation

1 flash per sec: Grease cartridge empty
1 flash per 0.5 sec: Defective decompression, pump pressurized,
pressure detected, fuse blown
SETTING GREASING TIME

The set time and greasing frequency limit differs according to the operating condition and greasing plan for the
machine, so set the following items to carry out suitable centralized greasing.
Greasing interval (Hr): Greasing interval for automatic operation
Greasing time (min): Length of time pump is operated for each greasing operation
Greasing frequency limit (times): No. of times for operating pump before the 1000 cc grease cartridge becomes
empty
The settings when shipping from the factory are as follows.
Greasing interval: 3 hours
Greasing time: 7 minutes
Greasing frequency limit: 100 times
The grease level alarm is set to sound after 300 hours on the hourmeter (when normal operation).
NOTICE
Be careful since the life of grease cartridge will be shortened if the greasing interval becomes shorter. Also, if the greasing interval
becomes shorter, the amount of grease dripping from the tip of the working machine increases. It may make the machine and
sorrounding area dirty.
SETTING GREASING TIME IN COLD AREAS

In cold temperatures, the viscosity of the grease rises, so it is necessary to increase the greasing time.
For example, if the machine is used at temperatures below -20°C (-4°F), set the greasing time to 20 minutes (code
No. 7). In addition, use lithium-based grease No. 0.
When changing the set value, please consult your Komatsu distributor.
6 - 40
.
METHOD OF SETTING
When setting the various items, the value is not input directly. Select the code number from the set code table below,
and set as follows.
SETTING CODE TABLE
NOTICE
When using the machine at ambient temperatures of below -20°C (-4°F), set to greasing time (b) at code No. 7.
PROCEDURE FOR SETTING

1. Stop the working machine on the flat and hard ground, and stop the engine.
2. Set the work equipment lock lever at LOCK position and set the starting switch at ON position.
3. Turn the starting switch to START and start the engine.
4. Press the LEVEL and ITEM keys at the same time to set to the
setting mode.
5. Press the ITEM key 1 or more times to select the item to be set.
REMARK
Each time the ITEM key is pressed, the setting item is changed: a
→ b → c → a.
6. When the item to be set flashes, press the LEVEL key.

The set item and numeral are displayed alternately (a →→ 0 →→ a →→ 0).
7. Refer to the setting code table and press the ITEM key 1 or more times to select the code number to be set.
REMARK
Each time the ITEM key is pressed, the code number (numeric portion) goes up by 1.
8. When the code number that is to be set flashes, press the SET
key to carry out the setting.
6 - 41
.
9. Repeat Steps 6 to 8 to set all of the items a, b, and c. After

completing the setting, press the ESC key to leave the setting
mode.
REMARK
Even if it is desired to change only 1 item, always carry out the
setting according to Steps 4 to 8. After completing the setting,
always press the ESC key to leave the setting mode.
If the power is then turned ON, the count for the greasing interval
will start immediately after the ESC key is pressed. Part of the
display segment flashes to indicate that the system is counting.
After setting, the set value is retained in memory even if the power
is turned OFF.
CHECK AMOUNT OF GREASE

2. Check the display of the pilot lamp on the machine monitor.
If the pilot lamp is flashing at 1-second intervals, it means that
the grease cartridge is empty.
Replace the grease cartridge with a new cartridge.
REPLACEMENT OF GREASE CARTRIDGE

WARNING
Air bleeding of pump involves danger because of high pressure. Ask your Komatsu distributor for air bleeding.
Be careful of the force applied by spring (2) installed inside the cover.
NOTICE
After replacing cartridge,make sure to reset number counter on controller. (Refer to "TROUBLESHOOTING (PAGE 6-44)".)
Replace grease cartridge according to procedure described below.
6 - 42
.
1. Remove cover by turning cartridge cover (1) approx. 60

degrees to the left.
2. Remove grease cartridge (3) by turning it to the left. Do not

detach seal cap (4) at this time.
3. Detach cap (5) and middle plug (6) from new grease cartridge
and tightly screw it in.
Screw in tightly to ensure that no air enters.
4. When fixing, if grease cartridge is pressed slightly and grease
comes out and deposits in a heaped shape, and if grease
cartridge is screwed into suction port connector under above
conditions,no air will enter. (Max. No. of turns is approx. 5)
5. Turn the cover to right and tighten it until securely fixed. If not
tightened well, there is a possibility that it will work loose due to
machine vibration.
Use the grease cartridge shown below.
Part No. Part name Q'ty Capacity

421-S95-3340 Cartridge 1 1000cc
6 - 43
.
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM

Basically, the power source input to the lubrication controller should be DC24V, but use a maximum limit of 30V.
The grease nipple installed to the service port used for initial charging of the divider valve has a ball check
structure, so it may leak if dirt gets stuck in it.
Check it from time to time, and replace the grease nipple immediately if any grease is leaking.
When carrying out initial operation or when the grease tank is empty, air may get into the piston portion of the
pump. If the pressure does not rise within the specified time when running the pump, and an error is displayed
for the controller, bleed the air.
If the divider valve or grease piping are removed when replacing the attachment on the machine, handle carefully
to prevent any damage. When storing or installing again, be extremely careful to prevent the entry of air, and
particularly dirt. If there is any air in the system, bleed the air immediately.
TROUBLESHOOTING
If any abnormality occurs in the greasing system, the error codes will flash alternately to display the type of
abnormality.
Error code Item Cause Remedy

E→a Defective Air in main piping Run pump as necessary and release
pressurizing of grease from end of piping to bleed air
pump Air inside pump Release grease from air bleed in pump to
bleed air
Grease tank is empty Add grease
Grease leaking from main Check, tighten connections of main piping
piping (including hoses)
E→b Abnormality in Abnormality in Disassemble pressure-releasing portion
release of pressure-releasing structure carefully, then check and clean
pressure built into pump
Abnormality in Check limit switch at pressure-detection
pressure-detection portion
equipment built into pump
E→c Abnormality in Abnormality in Check limit switch at pressure- detection
pressure pressure-detection portion
detection equipment built into pump
Abnormality in Disassemble pressure-releasing portion
pressure-releasing structure carefully, then check and clean
built into pump
E→0 Empty tank Greasing frequency limit Add grease
has been reached Reset frequency counter to zero.
Grease added during Confirm that 0 flashes 3 times on
frequency count 7-segment LED by pressing reset button
on controller for more than 5 seconds.
6 - 44
.
ATTACHMENTS, OPTIONS HANDLING JOYSTICK STEERING SYSTEM
HANDLING JOYSTICK STEERING SYSTEM

To enable you to use the joystick steering safely and efficiently, please read the following before using it.
(1) Shift up switch (7) Horn switch

(2) Shift down switch (8) Console lock lever
(3) FNR switch (9) Height adjustment lock lever
(4) Joystick steering lever (10) Angle, fore/aft adjustment lock lever
(5) Joystick ON/OFF switch (11) Console
(6) HI/LOW selector switch
SHIFT UP, SHIFT DOWN SWITCHES

These switches (1) and (2) are used to shift up or down in the
manual shift mode.
Press (1): Shift up
Press (2): Shift down
These switches are not used in the auto shift mode.
6 - 45
.
HANDLING JOYSTICK STEERING SYSTEM ATTACHMENTS, OPTIONS
FNR SWITCH
The F/N/R switch (3) at the top of the joystick steering lever is used
to switch the transmission between FORWARD and REVERSE.
(F) position: FORWARD

(N) position: NEUTRAL
(R) position: REVERSE
Use the shift up and shift down switches at the top of the joystick
to change the speed range.
JOYSTICK STEERING LEVER

Use this lever (4) to steer the machine to the left or right.
When traveling, operate this lever in the direction to turn the
machine.
(a): Left turn

(b): Right turn
(N): Neutral
JOYSTICK ON/OFF SWITCH

When this switch (5) is turned ON, the joystick steering is switched
ON.
Position (a): ON (possible to steer with joystick)
Position (b): OFF (impossible to steer with joystick)
HI/LOW SELECTOR SWITCH

This switch (6) is used to switch the steering speed between HIGH
and LOW.
Position (a): HI
The articulating speed of the machine is high in relationship to the
operation of the joystick, so this setting is suitable for
comparatively fast cycle times.
Position (b): LOW

The articulating speed of the machine is low in relationship to the
operation of the joystick, so this setting is suitable for operations
loading loose materials and materials that easily spill.
6 - 46
.
HORN SWITCH
Press this switch (7) at the top of the joystick to sound the horn.
By using this switch, it is possible to sound the horn without taking
your hand off the joystick.
CONSOLE LOCK LEVER

For details of this lever (8), see "GETTING IN OR OUT OF OPERATOR'S CAB (PAGE 6-49)".
HEIGHT ADJUSTMENT LOCK LEVER

For details of this lever (9), see "ADJUSTMENT OF JOYSTICK CONSOLE (PAGE 6-49)".
ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER

For details of this lever (10), see "ADJUSTMENT OF JOYSTICK CONSOLE (PAGE 6-49)".
STRUCTURE AND FUNCTION OF JOYSTICK STEERING

The joystick steering system is a system used to steer wheel
loaders with a lever instead of a steering wheel.
The joystick enables steering with small, light movements, and
helps to reduce operator fatigue.
When joystick ON/OFF switch (1) is turned ON, it becomes

possible to operate the steering with the joystick.
When the joystick steering is in use, the joystick pilot lamp on the
machine monitor lights up.
On machines equipped with the joystick steering system, it is
possible to use joystick ON/OFF switch (1) to select the steering
and transmission operation method as shown in the table below.
In addition, on machines equipped with joystick steering, the
transmission auto shift function is also included.
The differences between operation using the joystick and
operation using the steering wheel are as follows.
6 - 47
.
Selection Operation using joystick Operation using steering wheel
Joystick ON/OFF switch ON OFF
Steering using joystick (steering with

Steering Steering using steering wheel
steering wheel is also possible)
Operation using FNR switch Operation using transmission
F/N/R
at top of joystick directional lever
Transmission
Auto Auto
type
Shift mode
Transmission selector Manual Auto (L, M, H) Manual Auto (L, M, H)
switch
Speed range
Automatic Automatic
selection using
Selection of gearshifting Operation using gearshifting
shift up, shift down
speed range according to travel gearshift lever according to travel
switches at top of
speed speed
joystick*
*: Does not shift up above speed range of gearshift lever.
OPERATION USING JOYSTICK LEVER AND OPERATION USING STEERING WHEEL
CAUTION
If the directional lever and joystick FNR switch are not at the neutral position, the neutral interlock circuit makes it impossible
to switch the transmission directional control (when the joystick ON/OFF switch is ON, it is switched from the direc-
tional lever to the joystick FNR switch; when the joystick ON/OFF switch is OFF, it is switched from the joystick FNR switch to
the directional lever).
Do not use the joystick when traveling on public roads.
Select joystick operation or steering wheel operation according to the work.

Steering using joystick
This is suited for continuous loading operations on jobsites with ample space where the loading operation can be
carried out with a comparatively relaxed cycle time.
Because operations can be carried out with a small movements and light operating effort, this is also suitable for
reducing operator fatigue when operating continuously.
Steering using steering wheel
This provides excellent fine control and ability to travel straight, so it is suitable for travel between jobsites and for
load and carry operations. In addition, it is also suitable for short cycle loading operations because the upper part
of the operator's body is supported by the steering wheel when frequently switching between FORWARD and
REVERSE.
6 - 48
.
GETTING IN OR OUT OF OPERATOR'S CAB

WARNING
Always spring the joystick console up before getting in or out of the operator's cab.
If the console is sprung up, the safety switch is turned OFF and the joystick is automatically stopped from operating.
The joystick console is a spring-up type to make it easier for the operator to get in and out of the operator's cab.
If the joystick is moved accidentally when the engine is running, the machine may articulate unexpectedly. To
prevent this danger, always spring the joystick console up when not using the joystick for operations and when
getting in or out of the operator's cab.
1. Set lock lever (1) to the FREE position.
2. Spring joystick console (2) up.
Turn it at least 90 degrees.
The safety switch is turned OFF and the joystick cannot be
operated.
3. When operating, lower joystick console (2) and push lock lever
(1) down to the LOCK position. The safety switch is turned ON
and the joystick can be operated.
ADJUSTMENT OF JOYSTICK CONSOLE

WARNING
Stop the machine on level ground in a safe place when carrying out the adjustment.
Carry out the adjustment before starting operations or when changing operator shifts.
Put your back against the backrest of the operator's seat and adjust the seat so that it is possible to depress the brake fully,
then adjust the console.
Adjusting height
1. Operate lever (1) in the cancel direction and loosen the lock.
2. Adjust the height of the console and set joystick (2) to the
desired position.
3. After setting, operate lever (1) to the LOCK position to lock the
console securely in position.
Adjusting angle, fore/aft position

1. Operate lever (3) in the cancel direction and loosen the lock.
2. Adjust the console and set joystick (2) to the desired position.
Amount of fore/aft adjustment: 45 mm (1.8 in)
3. After setting, operate lever (3) to the LOCK position to lock the console securely in position.
6 - 49
.
OPERATION METHOD OF JOYSTICK STEERING SYSTEM

WARNING
It is dangerous to turn the machine suddenly at high speed, or to turn on steep hills. Do not operate the steering in such
conditions.
When turning, the articulation stops at the position where the steering wheel is turned to, but if the joystick is held in the tilted
position, the body will articulate fully.
The feeling when operating the steering with the joystick is different from when operating with the steering wheel, so be
extremely careful until you have become used to operating the joystick.
When the joystick ON/OFF switch is at the ON position, if the directional lever is operated to F or R, the machine will travel in
forward or reverse according to the operation of the directional lever, regardless of the position of the FNR switch on the head
of the joystick lever. Priority is given to the operation of the directional lever, so be careful when operating.
. When this is done, the central warning lamp lights up and the alarm buzzer sounds.
. Set the directional lever and FNR switch on the head of the joystick to the N position.
Check the adjustment and operation before starting the engine. For details, see "CHECK BEFORE STARTING
ENGINE, ADJUST (PAGE 3-90)".
1. Before starting the engine, check the operation of the joystick
lever steering, check that the transmission directional lever is
at N, and that the surrounding area is safe.
REMARK
Under the following conditions, a warning may be given when the
engine is started.
If the FNR switch on the joystick is at F or R, the joystick pilot
lamp flashes, the central warning lamp lights up, and the alarm
buzzer sounds.
In this condition, the engine will not start, so set the FNR switch
to N.
If the joystick is not at the N position, the joystick pilot lamp
flashes, the central warning lamp lights up, and the alarm
buzzer sounds.
In this condition, the engine will not start, so set the joystick to
the N position.
2. Press the (a) part of the joystick ON/OFF switch to turn it ON.
6 - 50
.
3. Operate the joystick in direction (b) to turn the machine to the

right; operate it in direction (a) to turn the machine to the left.
The greater the angle of operation, the faster the articulating
speed becomes.
4. It is possible to switch the articulating speed with the HI/LOW

selector switch.
Select the speed to match the operation.
5. When the machine has articulated to the desired angle, return
the joystick to the N position.
The joystick will return automatically to the N position.
6. To return the direction of travel of the machine so that it travels
in a straight line, operate the joystick in the opposite direction
from the N position (for example, when the machine is
articulated to the right, operate the joystick to the left).
7. Use the FNR switch at the top of the joystick lever to set the
transmission to the direction of travel.
N position: NEUTRAL
F position: FORWARD
R position: REVERSE
If the position of the directional lever and the FNR switch are
different, the joystick pilot lamp flashes, the warning lamp lights
up, and the alarm buzzer sounds.
In this condition, the machine will travel in the direction set by
the directional lever, so set the directional lever to N.
8. To change the speed range, use shift up switch (1) or shift

down switch (2) on the joystick.
REMARK
The joystick steering is unstable and dangerous to operate at high
speeds, so it is set so that the machine cannot travel in 4th.
When joystick operation is selected, if the gearshift lever is moved
to 4th, or the joystick ON/OFF switch is turned ON when the
gearshift lever is at 4th, the central warning lamp lights up and the
alarm buzzer sounds.
Set the gearshift lever within the range from 1st to 3rd.
In addition, when joystick operation is selected, for machines
equipped with a torque converter lock up (option), the system is
designed so that the machine does not travel at high speed even
if the torque converter lock up switch is turned ON.
6 - 51
.
9. Press part (b) of the joystick ON/OFF switch to turn it OFF.

The joystick operation is then canceled.
6 - 52
.
ATTACHMENTS, OPTIONS HANDLING EPC WORK EQUIPMENT LEVER
HANDLING EPC WORK EQUIPMENT LEVER

OPERATIONAL FEATURES
EPC (Electronic Pilot Control) work equipment levers are offered as an option.
To improve the operating efficiency, the following three functions are provided.
Modulation function to prevent shock when stopping the bucket
Function to set the bucket stop position at two places - Top and Bottom (remote positioner)
It is possible to set the stop position from the operator's seat.
Semiautomatic digging bucket - control function
Bucket tilt operation can be automatically done when digging.
Semiautomatic digging offers two selectable modes - Soft and Hard.
SWITCHES
(1) Semi auto digging switch (3) Remote positioner lower mode switch
(2) Remote positioner raise mode switch (4) Remote positioner raise/lower set switch
6 - 53
.
HANDLING EPC WORK EQUIPMENT LEVER ATTACHMENTS, OPTIONS
WORK EQUIPMENT LOCK LEVER

WARNING
Before standing up from the operator's seat, set the work equipment lock lever securely to the LOCK position. If the work
equipment lock lever is not at the LOCK position, and work equipment control lever (A) is touched by mistake, it may lead to
a serious accident.
If the work equipment lock lever is not placed securely at the LOCK position, the work equipment may move, and this may lead
to a serious accident or personal injury. Check that the lever is in the position shown in the diagram.
When pulling up or pushing down the work equipment lock lever, be careful not to touch work equipment control lever (A).
This lever is a lock device for the work equipment control lever.
Push the work equipment lock lever down to lock it.
REMARK
This lever electrically locks the hydraulic circuit for the work
equipment, so if it is at the LOCK position, the work equipment will
not move even when work equipment control lever (A) is operated.
If the work equipment control lever is operated when this lever is at
the LOCK position, the central warning lamp lights up and the
alarm buzzer sounds. At the same time, "E00 WORK LEVER
POSI" is displayed on the character display.
SEMI AUTO DIGGING OPERATIONS
SEMI AUTO DIGGING OPERATIONS

Semi auto digging controls the bucket tilt operation automatically in order to make bucket operations easier for the
operator and reduce operator fatigue.
When doing the semi auto diggig operations, refer to the section of "DIGGING OPERATIONS (PAGE 3-127)" in the
chapter, "WORK POSSIBLE USING WHEEL LOADER (PAGE 3-127)".
SEMI AUTO DIGGING SWITCH

This switch turns the semi auto digging ON or OFF.
Position (a): HARD mode
The bucket tilt actuation is controlled intermittently.
Use this mode when handling heavy load materials.
Position (b): SOFT mode
The bucket tilt actuation is controlled continuously.
Use this mode when handling crushed rock or other
light load materials.
N position: Semi auto digging is switched OFF
In positions (a) and (b), the pilot lamp inside the switch lights up.
6 - 54
.
METHOD OF OPERATION
1. Turn the semi auto digging switch on the right switch panel ON
(select SOFT or HARD).
When the switch is turned ON, the pilot lamp inside the switch
lights up.
Position (a): HARD mode
Position (b): SOFT mode
N position: OFF
REMARK
For details of the selection of SOFT or HARD, see "SELECTING
DIGGING PATTERN (PAGE 6-55)".
2. Lower the bucket to the ground as in the normal digging work and travel the machine forward. When the bucket
teeth dig into the ground, press the kick-down switch.
3. If the bucket tip is dug into the ground at boom RAISE, the bucket will automatically start tilting back.
Besides, when the boom hydraulically stalls in the digging work where the boom lever is pulled back and held
in the detent, the machine automatically starts the bucket to tilt back and maintains the optimum boom raise
speed thereafter.
The semi-auto digging pilot lamp on the main monitor lights up during automatic digging work.
SELECTING DIGGING PATTERN

The following 2 modes can be selected for operating the bucket tilt.
The semi auto digging switch on the right switch panel is used to select the mode.
(1) SOFT mode
This mode is effective when handling crushed rock or other light load materials.
The bucket tilt actuation is controlled continuously.
(2) HARD mode
This mode is effective when handling heavy load materials.
The bucket tilt actuation is controlled intermittently.
MANUAL OPERATION DURING AUTOMATIC CONTROL

It is possible to operate the bucket control lever to the TILT or DUMP position during automatic operation of the
bucket tilt.
As the bucket speed is proportional to the amount of lever operation, the bucket motion is the addition of the lever
operation and bucket speed programmed by the automatic control system.
END OF CONTROL
When the bucket reaches the end of the tilt, the control ends.
6 - 55
.
HANDLING EPC WORK EQUIPMENT LEVER ATTACHMENTS, OPTIONS
METHOD OF REMOTE POSITIONER

It is possible to set the lift arm stop position by operating remote
positioner RAISE mode switch (1), remote positioner LOWER
mode switch (2), and remote positioner RAISE/LOWER set switch
(3) on the right switch panel.
REMARK
The RAISE mode is used when setting the lift arm position at a
point where the lift arm is above the horizontal position; the
LOWER mode is used when setting the stop position at a point
where the lift arm is below the horizontal position.
REMOTE POSITIONER RAISE MODE SWITCH

Use this switch (1) to turn on the remote positioner RAISE mode
(operating the lift arm at above the horizontal position).
Position (a): RAISE mode ON
Position (b): OFF
REMOTE POSITIONER LOWER MODE SWITCH

Use this switch (2) to turn on the remote positioner LOWER mode
(operating the lift arm at below the horizontal position).
Position (a): LOWER mode ON
Position (b): OFF
6 - 56
.
REMOTE POSITIONER RAISE/LOWER SET SWITCH

Use this switch (3) to set the stopping position of the lift arm for the
remote positioner.
Position (a): After turning the remote positioner RAISE mode
switch ON, raise the lift arm to the desired position
above horizontal, then press the bottom (a) of this
switch to set the top lift arm stop position at that point.
Position (b): After turning the remote positioner LOWER mode
switch ON, lower the lift arm to the desired position
below horizontal, then press the bottom (b) of this
switch to set the bottom lift arm stop position at that
point.
If the setting is carried out properly, the buzzer will give short sounds.
If the setting cannot be carried out, the buzzer gives a long sound.
METHOD OF OPERATION
Setting with RAISE (or LOWER) mode
1. Press the top (a) of remote positioner RAISE (or LOWER)

mode switch (1) (or (2)) to turn the mode ON.
2. Raise (or lower) the bucket to the desired position.
3. In the case of the RAISE mode, press the top (a) (or the bottom
(b) for the LOWER mode) of remote positioner RAISE/LOWER
set switch (3).
The lift arm stop position is set.
If the setting is carried out properly, the buzzer will give short
sounds.
If the setting cannot be carried out, the buzzer gives a long
sound, so repeat the procedure from Step 1.
6 - 57
.
HANDLING MULTI FUNCTION MONO-LEVER ATTACHMENTS, OPTIONS
HANDLING MULTI FUNCTION MONO-LEVER

(1) Work equipment lever (4) FNR switch

(2) Kickdown switch (5) Directional selector switch actuation switch
(3) Hold switch (6) Directional selector pilot lamp
6 - 58
.
ATTACHMENTS, OPTIONS HANDLING MULTI FUNCTION MONO-LEVER
WORK EQUIPMENT LEVER

This lever (1) is used to control the lift arm and bucket.
LIFT ARM OPERATION

NOTICE
Position (a): RAISE

When the work equipment control lever is pulled
further beyond 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
Position (c): LOWER
Position (d): FLOAT
BUCKET OPERATION
Position (e): TILT
When the work equipment control lever is pulled
further beyond the TILT position, the lever is stopped
in this position until the bucket reaches the preset
position of the positioner, and the lever is returned to
the HOLD position.
Position (b): HOLD
Position (f): DUMP
NOTICE
Do not use FLOAT position when lowering the bucket. Use FLOAT position when leveling, see "LEVELING OPERATIONS (PAGE
3-130)".
6 - 59
.
KICKDOWN SWITCH
When the gearshift lever is in 2nd, if switch (2) is pressed, the
transmission will shift down to 1st.
Use this when you need to increase the drawbar pull in digging
operations.
If the transmission is in auto-shift, and the travel speed is below

12.5 km/h (7.8 MPH) in any speed range when traveling in either
forward or in reverse, the kick-down switch is actuated and it is
possible to shift down to 1st.

Even if the travel speed is more than 12.5 km/h (7.8MPH), this switch can be used to shift the transmission down.
Each time the kick-down switch is pressed, the speed range will shift down 1 range at a time (F4 -> F3 -> F2).
When the torque converter is in the lockup condition (if equipped), the lockup is canceled.
REMARK
When canceling the kick-down, operate the directional lever or the FNR switch. In manual shift, it can be
canceled by operating the speed lever to any position other than 2nd. It is also possible to cancel the kick-down
by turning the starting switch OFF.
In auto-shift, if the travel speed becomes high after the kick-down, the gear will be shifted up by the auto-shift.
In auto-shift, when traveling at more than 25 km/h (15.5 MPH) in 3rd or at more than 35 km/h (21.7 MPH) in 4th,
even if the kick-down switch is pressed, the transmission will not shift down. This is to prevent overrun of the
engine.
HOLD SWITCH
To fix the speed range when traveling in automatic transmission,
press this switch (3). The transmission will be fixed in the speed
range displayed on shift indicator (A) on the machine monitor and
shift hold pilot lamp (B) will light up.
When the switch is pressed again, the display goes out.
Use this function to select the desired speed range when traveling
up or down hills or when carrying out operations such as grading.
REMARK
When the torque converter is in the lock-up condition (if
equipped), the transmission cannot be fixed.
When canceling the shift hold, operate the directional lever or
the FNR switch. It can also be canceled by operating the speed
lever and by switching the shift/manual selector switch to
MANUAL. Is also possible to cancel the shift hold by turning the
starting switch OFF.
6 - 60
.
FNR SWITCH
This switch (4) is used to change the direction of travel of the
machine.
Position (F): FORWARD
Position (N): Neutral
Position (R): REVERSE
Before operating this switch, check that the condition is as follows.
Directional lever is at N
Directional selector switch actuation switch is at ON
If the condition is not as above, the switch will not work.
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH

When this switch (5) is pressed, the FNR switch on the head of the
multifunction mono-lever is activated.
Position (a): ON
The pilot lamp inside the switch and the directional selection pilot
lamp on the machine monitor light up, and the FNR switch is
activated.
Position (b): OFF
The FNR switch is not activated.
DIRECTIONAL SELECTOR PILOT LAMP

This monitor (6) lights up when the directional selector switch
actuation switch on the right switch panel is turned ON. It indicates
that it is possible to operate the travel direction of the machine with
the FNR switch on the head of the multifunction mono-lever.
6 - 61
.
USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE

WARNING
When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot
behind the machine, so be particularly careful when changing direction to travel in reverse.
When the directional selector switch actuation switch is at the ON position, if the directional lever is operated to F or R, the
machine will travel in forward or reverse according to the operation of the directional lever, regardless of the position of the
FNR switch on the head of the multi-function lever.
Priority is given to the operation of the directional lever, so be careful when operating.
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 sufficiently, then change the
direction of travel. (Max.speed for changing direction: 12 km/h (7.5 MPH))
1. Place the directional lever at the N position.
2. Turn on directional selector switch on the right side of switching

panel that enables directional selection.
Position (a): ON
Position (b): OFF
The pilot lamp inside the switch and the directional selection pilot
lamp on the machine monitor light up, and the FNR switch is
activated.
6 - 62
.
3. Push the FNR switch on the head of the multifunction

mono-lever to the desired position.
If the directional selector pilot lamp on the machine monitor flashes, the switch or the lever is in one of the following
conditions.
When the directional selector switch actuation switch is at the OFF position, if the FNR switch is operated to F (or
R):
The pilot lamp flashes, and at the same time, the central warning lamp lights up and the alarm buzzer sounds.
At the same time, "E00 SHIFTLEVER NEUT" is displayed on the character display.
Set the FNR switch to the N position.
When the engine is started, if the directional selector switch is at the ON position and the directional lever is at
N, and the FNR switch is operated to F (or R):
Set the FNR switch to the N position.
If the directional selector switch is at the ON position and the FNR switch is operated to F (or R):
In this condition, the machine will travel in forward or reverse according to the operation of the directional lever.
Set the directional lever and the FNR switch on the head of the multi-function lever to the N position.
6 - 63
.
.
INDEX
INDEX
<A> HANDLING AUTO-GREASING SYSTEM 6- 38

ADJUSTING WORK EQUIPMENT METHOD OF OPERATING
POSTURE 3-135 AUTO-GREASING SYSTEM 6- 38
AIR CONDITIONER 3- 77 PRECAUTIONS WHEN HANDLING
AM/FM RADIO 3- 63 AUTO-GREASING SYSTEM 6- 44
AM/FM RADIO-CASSETTE STEREO 3- 69 TROUBLESHOOTING 6- 44
HANDLING CAB WIPER 3- 89
<C> HANDLING EPC WORK EQUIPMENT
CAB DOOR OPEN LOCK 3- 59 LEVER 6- 53
CAB WINDOW OPEN LOCK CANCEL METHOD OF REMOTE POSITIONER 6- 56
KNOB 3- 59 OPERATIONAL FEATURES 6- 53
CAP WITH LOCK 3- 56 SEMI AUTO DIGGING OPERATIONS 6- 54
CHECK BEFORE STARTING ENGINE, SWITCHES 6- 53
ADJUST 3- 90 HANDLING JOYSTICK STEERING
CHECKS AFTER COMPLETION OF SYSTEM 6- 45
OPERATION 3-139 ADJUSTMENT OF JOYSTICK
COLD WEATHER OPERATION 3-148 CONSOLE 6- 49
AFTER COLD WEATHER 3-149 EXPLANATION OF COMPONENTS 6- 45
PRECAUTIONS AFTER GETTING IN OR OUT OF
COMPLETION OF WORK 3-149 OPERATOR'S CAB 6- 49
PRECAUTIONS FOR LOW OPERATION METHOD OF JOYSTICK
TEMPERATURE 3-148 STEERING SYSTEM 6- 50
WARMING-UP OPERATION FOR STRUCTURE AND FUNCTION OF
STEERING HYDRAULIC CIRCUIT JOYSTICK STEERING 6- 47
IN COLD WEATHER 3-150 HANDLING LOAD METER 6- 3
CONTROL LEVERS, PEDALS 3- 50 GENERAL LOCATIONS 6- 3
HANDLING LOAD METER DISPLAY 6- 9
<E> LOAD METER FUNCTIONS 6- 5
ENGINE SERIAL NO. PLATE 1- 6 METHOD OF SETTING TIME ON
EXPLANATION OF COMPONENTS 3- 6 CLOCK 6- 30
PRINTER OUTPUT 6- 32
<F> HANDLING MULTI FUNCTION
FOREWORD 1- 2 MONO-LEVER 6- 58
FRAME LOCK BAR 3- 58 EXPLANATION OF COMPONENTS 6- 58
FUSE 3- 60 USING FNR SWITCH TO CHANGE
BETWEEN FORWARD AND
<G> REVERSE 6- 62
GENERAL PRECAUTIONS 2- 11 HANDLING OIL, FUEL, COOLANT, AND
GENERAL VIEW 3- 2 PERFORMING OIL CLINIC 4- 4
GENERAL VIEW OF CONTROLS AND HANDLING THE TIRES 3-140
GAUGES 3- 3 HANDLING TORQUE CONVERTER
GENERAL VIEW OF MACHINE 3- 2 LOCK-UP 6- 35
GREASE PUMP 3- 59 GENERAL LOCATIONS 6- 35
GUIDES TO MAINTENANCE 4- 2 METHOD OF OPERATION 6- 36
WARNING/LIMIT FUNCTIONS FOR
<H> TRAVEL SPEED 6- 37
HANDLING AUTO AIR CONDITIONER 3- 82
7-1
.
INDEX
<I> <R>
INTRODUCTION 1- 5 RECOMMENDED FUEL, COOLANT,
FRONT/REAR, LEFT/RIGHT AND LUBRICANT 4- 9
DIRECTIONS OF MACHINE 1- 5 RECOMMENDED BRANDS,
RECOMMENDED QUALITY FOR
<L> PRODUCTS OTHER THAN
LIFTING MACHINE 3-146 KOMATSU GENUINE OIL 4- 11
LOADING, UNLOADING WORK WITH USE OF FUEL, COOLANT AND
TRAILERS 3-142 LUBRICANTS ACCORDING TO
LOCKING 3-139 AMBIENT TEMPERATURE 4- 10
LONG-TERM STORAGE 3-151
AFTER STORAGE 3-152 <S>
BEFORE STORAGE 3-151 SAFETY 2- 2
DURING STORAGE 3-151 SAFETY INFORMATION 1- 3
SAFETY LABELS 2- 5
<M> LOCATION OF SAFETY LABELS 2- 5
MACHINE MONITOR 3- 6 SAFETY LABELS 2- 6
MAINTENANCE SCHEDULE CHART 4- 14 SELECTING BUCKET AND TIRES 6- 2
MOVING THE MACHINE SERVICE PROCEDURE 4- 16
(DIRECTIONAL, SPEED), STOPPING CHECK BEFORE STARTING 4- 41
THE MACHINE 3-113 EVERY 100 HOURS SERVICE 4- 43
<N> EVERY 2000 HOURS SERVICE 4- 56
NECESSARY INFORMATION 1- 6 EVERY 250 HOURS SERVICE 4- 45
<O> EVERY 50 HOURS SERVICE 4- 42
OPERATION 3- 90 EVERY 500 HOURS SERVICE 4- 51
OPERATION OF WORK EQUIPMENT 3-125 EVERY 8000 HOURS SERVICE 4- 66
OPERATIONS AND CHECKS AFTER INITIAL 250 HOURS SERVICE 4- 16
STARTING ENGINE 3-110 WHEN REQUIRED 4- 17
OUTLINE OF ELECTRIC SYSTEM 4- 7 SLOW BLOW FUSE 3- 61
OUTLINES OF SERVICE 4- 4 SPECIFICATIONS 5- 2
STANDARD TIGHTENING TORQUES
<P> FOR BOLTS AND NUTS 4- 12
PARKING MACHINE 3-137 STARTING ENGINE 3-106
PERIODIC REPLACEMENT OF SAFETY STEERING TILT LOCK LEVER 3- 55
CRITICAL PARTS 4- 13 STOPPING ENGINE 3-112
POSITION OF SERVICE METER 1- 7 SWITCHES 3- 36
POWER OUTLET 3- 62
PRECAUTIONS FOR MAINTENANCE 2- 32 <T>
PRECAUTIONS FOR OPERATION 2- 20 TABLE TO ENTER SERIAL NO. AND
BATTERY 2- 29 DISTRIBUTOR 1- 7
OPERATION 2- 22 TORQUE LIST 4- 12
STARTING ENGINE 2- 20 TOWING PIN 3- 58
TOWING 2- 31 TRANSPORTATION 3-142
TRANSPORTATION 2- 28 TRANSPORTATION PROCEDURE 3-142
PRECAUTIONS FOR OPERATION 3-133 TROUBLESHOOTING 3-153
PRECAUTIONS WITH TIRES 2- 39 IF BATTERY IS DISCHARGED 3-159
PRODUCT IDENTIFICATION NUMBER METHOD OF TOWING MACHINE 3-154
(PIN)/MACHINE SERIAL NO. PLATE 1- 6 OTHER TROUBLE 3-162
7-2
.
INDEX
WHEN MACHINE RUNS OUT OF

FUEL 3-153
TURNING 3-123
<W>
WEAR PARTS 4- 8
WEAR PARTS LIST 4- 8
WORK POSSIBLE USING WHEEL
LOADER 3-127
7-3
.
WA380-5 WHEEL LOADER

Form No. TEN00089-06
©
2018 KOMATSU
All Rights Reserved
Printed in Japan 07-18

Ten00089-06 Wa380-5 Wheel Loader

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Ten00089-06 Wa380-5 Wheel Loader

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TEN00089-06

WHEEL LOADER WA380 -5

Read this manual thoroughly and understand its contents fully.

Storage location for the Operation and Maintenance Manual:

FOREWORD SAFETY INFORMATION

Example of safety message using signal word

Other signal words

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

SAFETY INFORMATION FOREWORD

Example of safety label using words

Safety labels using pictogram

FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE

NECESSARY INFORMATION FOREWORD

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE

ENGINE SERIAL NO. PLATE

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

FOREWORD NECESSARY INFORMATION

POSITION OF SERVICE METER

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Engine serial No.

Product identification number (PIN)

STARTING ENGINE 3-106

PRECAUTIONS FOR OPERATION 2- 20

PRECAUTIONS FOR MAINTENANCE 2- 32

PRECAUTIONS WITH TIRES 2- 39

SAFETY SAFETY LABELS

LOCATION OF SAFETY LABELS

SAFETY LABELS SAFETY

(2) Caution for leaving the operator's seat (09654-03001)

(3) Caution when traveling in reverse

Please request part No. 421-93-23251 for this safety label.

SAFETY SAFETY LABELS

(4) Caution for going close to electric cables (09801-13001)

(5) Caution to keep away from movable parts (09162-23000)

(6) Caution for frame lock bar (09161-23000)

SAFETY LABELS SAFETY

(7) Caution for parking brake (421-93-23351)

(8) Warning for hot cooling water (09668-03001)

(9) Caution when oil is at high temperature (09653-03001)

(10) Caution for handling battery cable (09808-03000)

SAFETY SAFETY LABELS

(11) High pressure warning (09659-53000)

(12) Do not climb on fender (09805-03000)

(13) "Do not open when engine is running" sign

(14) "Do not come near machine" sign (09812-13000)

(15) "Do not go under work equipment" sign (09807-C0883)

SAFETY LABELS SAFETY

(16) "Do not modify ROPS" sign (09620-30201)

(17) Prohibited to start by short-circuiting (09842-A0481)

SAFETY GENERAL PRECAUTIONS

IF ABNORMALITIES ARE FOUND

CLOTHING AND PERSONAL PROTECTIVE ITEMS

FIRE EXTINGUISHER AND FIRST AID KIT

GENERAL PRECAUTIONS SAFETY

KEEP MACHINE CLEAN

INSIDE OPERATOR'S COMPARTMENT

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT

SAFETY GENERAL PRECAUTIONS

HANDRAILS AND STEPS