Komatsu WA320-5H Operation & Maintenance Manual
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Komatsu WA320-5H Operation & Maintenance Manual

Komatsu WA320-5H Operation & Maintenance Manual

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Operation & Maintenance
Manual
WHEEL LOADER
SERIAL NUMBERS WA320H50051 AND UP
Incorrect operation and maintenance of this machine
may be hazardous and cause injuries. The operator and
maintenance personnel must read this manual before
commencing operation or maintenance. Keep this
manual within reach at all times and ensure that
operating personnel read it at regular intervals.
NOTE
Komatsu has had the operating and maintenance instructions
translated into all the languages of the European Union.
Should you require a copy in another language please inquire
.
at your local dealer's
DANGER
VEAM240100
-5H

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Summary of Contents for Komatsu WA320-5H

  • Page 1 NOTE Komatsu has had the operating and maintenance instructions translated into all the languages of the European Union. Should you require a copy in another language please inquire...
  • Page 2 FOREWORD...
  • Page 3 If you sell the machine, be sure to give this manual to the new owners together with the machine. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
  • Page 4 The transmitter unit must be spatially separated from the vehicle’s electronic system q Make sure when installing the antenna that this is installed correctly with good earth connection between antenna and vehicle mass Also observe Komatsu and manufacturer’s installation instructions for wiring, installation and maximum permitted power consumption.

  • Page 5: Safety Information

    FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa- tions.
  • Page 6 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.

  • Page 7: Introduction

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

  • Page 8: Necessary Information

    FOREWORD NECESSARY INFORMATION NECESSARY INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. MACHINE SERIAL NO. PLATE AND POSITION On the center right of the front frame. ENGINE SERIAL NO. PLATE AND POSITION This is on the side face of the engine cover on the right side of the machine.

  • Page 9: Rops/Fops-Cab Serial No. Plate

    FOREWORD NECESSARY INFORMATION ROPS/FOPS-CAB SERIAL NO. PLATE This plate is located on the right inside cab on the rear beam. AXLE SERIAL NO. PLATE This plate is located on the right of front axle and on the left of rear axle. TRANSMISSION SERIAL NO.

  • Page 10: Position Of Service Meter

    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. Distributor name Address Service Personnel Phone/Fax...

  • Page 11: Table Of Contents

    POSITION OF SERVICE METER........................1-9 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ................. 1-9 CONTENTS ..............................1-10 DIMENSIONS, WEIGHTS AND OPERATING DATA ..................1-17 WA320-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA............... 1-17 CE-CONFORMING EQUIPMENT........................1-18 CE-CONFORMING EQUIPMENT........................ 1-18 MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93- H1900 ..............................

  • Page 12: Contents

    FOREWORD CONTENTS CENTRAL WARNING LAMP ........................3-7 CHARACTER DISPLAY PORTION ......................3-8 EMERGENCY STOP ITEM ........................3-14 CAUTION ITEMS............................ 3-16 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED................3-18 INSPECTION AND MAINTENANCE ITEM..................... 3-19 PILOT DISPLAY PORTION ........................3-22 METER DISPLAY PORTION........................3-25 OTHER FUNCTIONS OF MACHINE MONITOR..................
  • Page 13 ELECTRICAL SYSTEM ........................3-117 CHASSIS .............................. 3-118 ENGINE ..............................3-120 MAINTENANCE GUIDES TO MAINTENANCE ..........................4-2 OUTLINES OF SERVICE ........................... 4-4 HANDLING OIL, FUEL, COOLANT, GREASE AND CARRYING OUT KOWA (Komatsu Oil Wear Analysis)4-4 OIL ................................4-4 FUEL................................. 4-4 COOLANT..............................4-5 1-12...
  • Page 14 FOREWORD CONTENTS GREASE ..............................4-5 CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ................4-5 STORING OIL AND FUEL ........................4-6 FILTERS ..............................4-6 BIODEGRADABLE HYDRAULIC OIL AND LUBRICANTS ..............4-7 OUTLINE OF ELECTRIC SYSTEM....................... 4-7 WEAR PARTS ..............................4-8 WEAR PARTS LIST............................4-8 FUEL, COOLANT AND LUBRICANTS......................
  • Page 15 FOREWORD CONTENTS CHECK PLAY OF TURBOCHARGER ROTOR..................4-54 CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT........... 4-54 EVERY 2000 HOURS SERVICE ......................... 4-55 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT ......4-55 REPLACE HYDRAULIC TANK BREATHER ELEMENT ................ 4-56 CLEANING THE STRAINER OF THE BRAKE FILTER .................
  • Page 16 FOREWORD CONTENTS CENTRAL LUBRICATION SYSTEM ....................... 6-63 OPERATING THE CENTRAL LUBRICATION SYSTEM................6-63 DISPLAY AND CONTROL UNIT ......................... 6-63 LED-DISPLAY............................6-64 PUSHBUTTONS............................. 6-64 CHANGING THE LUBRICATION INTERVAL TIMES.................. 6-65 INDEX INDEX ................................. 7-3 NOTES NOTES................................8-2 1-15...
  • Page 17 FOREWORD CONTENTS 1-16...

  • Page 18: Dimensions, Weights And Operating Data

    FOREWORD DIMENSIONS, WEIGHTS AND OPERATING DATA DIMENSIONS, WEIGHTS AND OPERATING DATA WA320-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA WA320-5Abm Measurements, operating data Bucket capacity to ISO 7546 m³ Material density t/m³ Bucket weight without teeth 1.040 Static tipping load, straight 12.000 Static tipping load, 40°...

  • Page 19: Ce-Conforming Equipment

    CE-CONFORMING EQUIPMENT CE-CONFORMING EQUIPMENT CE-conforming equipment – Load Hydraulic Volume Weight Type Part No. Capacity pressure m³ 419-72-H2100 1.040 419-72-H2110 1.143 419-72-H2160 1.118 419-72-H2170 2.217 Bucket WA320-5H 419-72-H2120 2,85 1.254 419-72-H2180 2,85 1.325 419-72-H2130 1.265 419-72-H2140 1.363 419-72-H2150 1.472 GK100392 1-18...

  • Page 20: Manufacturer-Supplied Ce-Conforming Equipment, According To Document 421-93-H1900

    FOREWORD CE-CONFORMING EQUIPMENT MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900 The responsibility for observing valid regulations in the case of wheel loaders with "interchangeable equipment" (e.g. bucket or fork-lift) which was not supplied from works lies with the cus- tomer which was subsequently fitted to the machine. The directives for CE conformity and road-traffic registration are deemed to have been fulfilled when the manufacturer of the equipment confirms fulfilment of the form 421-93-H1900 along-...
  • Page 21 FOREWORD CE-CONFORMING EQUIPMENT d1=d2 GK100395 1-20...
  • Page 22 M A N U FA C T U R E R - S U P P L I E D C E - C O N F O R M I N G EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900 WA320-5H 421-93-H1900...
  • Page 23 FOREWORD CE-CONFORMING EQUIPMENT 1-22...

  • Page 24: Safety

    SAFETY...
  • Page 25 SAFETY...

  • Page 26: Safety Labels

    Always keep all safety labels clean. When cleaning them, use soap and water. Do not use organic solvents or gas- oline. These may cause the safety labels to peel off. Missing or damaged safety labels must be replaced. Order the new part from your Komatsu distributor. LOCATION OF SAFETY LABELS...

  • Page 27: Presentation Of Safety Labels

    Precautions when traveling in reverse Use Komatsu oil only (421-93-H1360) (421-93-H1390) Sign indicates to pre- vere severe injury or death Honk to alert people nearby.
  • Page 28 SAFETY SAFETY LABELS Do not enter (421-93-H1320) Precautions for safety bar (421-93-H1330) Sign indicates a crush Sign indicates a crush hazard between the hazard between the articulating parts of the articulating parts of vehicle. vehicle. Keep away from the Lock vehicle with lock vehicle when it is bar to avoid movement move.
  • Page 29 SAFETY SAFETY LABELS Do not climb on fender (421-93-H1400) Do not open when engine is running (09667-A0880) Sign indicates a hazard Sign indicates a hazard of falling. of rotating parts, such as belt. Do not stand on this Turn off engine before place here.

  • Page 30: General Precautions

    SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES q Only trained and authorized personnel can operate and maintain the machine. q Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. q If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
  • Page 31 SAFETY GENERAL PRECAUTIONS SAFETY FEATURES q Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. q Understand the method of use of safety features and use them properly. q Never remove any safety features.
  • Page 32 SAFETY GENERAL PRECAUTIONS ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT q Before standing up from the operator's seat (such as when adjusting the operator's seat), always lower the work equipment completely to the ground, set safety lock lever Free (1) to the LOCK position, pull parking brake lever (2) to the LOCK position, then stop the engine.
  • Page 33 SAFETY GENERAL PRECAUTIONS q To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps to ensure that you support yourself. q When entering the cab, open the cab door, push the door securely into catcher (1) to hold in position, then use the handrail on the inside to get on the machine.
  • Page 34 SAFETY GENERAL PRECAUTIONS DO NOT GET CAUGHT IN ARTICULATED PORTION q If the clearance at the articulating portion changes, it will lead to serious personal injury. Do not allow anyone to come inside the articulation range. q Never enter or put your hand, arm, or any part of your body in the movable portion between the work equipment and machine or between the cylinder and the work equipment.
  • Page 35 SAFETY GENERAL PRECAUTIONS FIRE PREVENTION q Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particu- larly flammable and can be hazardous. To prevent fire, always observe the following: q Do not smoke or use any flame near fuel or oil. q Stop the engine before refueling.
  • Page 36 Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. q Komatsu will not be responsible for any injuries, accidents, product failures or other property damages result- ing from modifications made without authorization from Komatsu.
  • Page 37 SAFETY GENERAL PRECAUTIONS SAFETY AT WORKSITE q Before starting operations, thoroughly check the work area for dangerous working conditions. q Inspect the surface of the soil in the working area and determine the optimum and safest procedure. q When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating.
  • Page 38 SAFETY GENERAL PRECAUTIONS q Even going close to high-voltage cables can cause electric shock, which may cause serious burns or even death. Always maintain a safe distance (see the table on the right) Safety Nominal Voltage between the machine and the electric cable. Check with Distance the local power company about safe operating procedure before starting operations.
  • Page 39 Do not allow other persons to approach during the opera- tion. q Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2-16...

  • Page 40: Precautions For Operation

    SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment con- trol lever, do not start the engine or touch the levers. 9JA05370A CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. q Remove all dirt from the surface of the window glass to ensure a good view.
  • Page 41 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN STARTING q Only start and operate the machine from the seat. Never try to start the engine by hot-wiring the ignition. This can cause fire, grave injuries or death. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a seri- ous bodily injury or fire.

  • Page 42: Operation

    SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS BEFORE OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. q Always fasten your seat belt. q Check the operation of travel, steering and brake systems, and work equipment control system.
  • Page 43 This may cause the tires to burst. If a tire bursts, it produces an extremely large destructive force, and this may cause serious injury or acci- dent. If you are going to travel continuously, please consult your Komatsu distributor. 2-20...
  • Page 44 SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. q When traveling on slopes, keep the bucket at height “A“ of approximately 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, quickly lower the bucket to the ground to help the machine to stop.
  • Page 45 SAFETY PRECAUTIONS FOR OPERATION PROHIBITED OPERATIONS q It is dangerous to excavate the bottom of a rock face. Never do this. q It is dangerous to use the bucket or lift arm for crane oper- ations, so do not carry out such operations. q Do not pass the bucket over the head of other workers or over the operator's seat of dump trucks or other hauling equipment.
  • Page 46 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN OPERATING q When using the machine, to prevent the machine from overturning due to overloading and to avoid damage to the work equipment, do not exceed the maximum permitted load or performance of the machine. q If the engine cannot be started again after it has stopped, immediately operate the work equipment control levers to lower the work equipment to the ground.
  • Page 47 SAFETY PRECAUTIONS FOR OPERATION OPERATE CAREFULLY ON SNOW q When working on snow or ice-covered surfaces, there is danger of the machine starting to skid even at a very flat angle. For this reason, drive slowly and avoid sudden starts, turns, or stops. q When driving on hill flanks covered with snow do not brake abruptly to stop the machine.

  • Page 48: Transportation

    PRECAUTIONS FOR OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.

  • Page 49: Battery

    SAFETY PRECAUTIONS FOR OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. q Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
  • Page 50 SAFETY PRECAUTIONS FOR OPERATION STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. q When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the opera- tor's seat and the other working with the battery).

  • Page 51: Towing

    SAFETY PRECAUTIONS FOR OPERATION TOWING WHEN TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selec- tion or inspection of the wire rope. For towing, see “TOWING THE MACHINE (3-111)“. q Always wear leather gloves when handling wire rope.

  • Page 52: Precautions For Maintenance

    SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG q Always attach the “DO NOT OPERATE“ warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.
  • Page 53 SAFETY PRECAUTIONS FOR MAINTENANCE MAINTENANCE WITH ENGINE RUNNING q Stop the machine on firm, level ground. q Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. q Lower the work equipment completely to the ground and stop the engine.
  • Page 54 SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows. q One worker must always sit in the operator's seat and be ready to stop the engine at any time.
  • Page 55 Do not hit or roll the accumulator, or subject it to any impact. q When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
  • Page 56 SAFETY PRECAUTIONS FOR MAINTENANCE WORKING UNDER THE RAISED BOOM WARNING Danger of injury! The raised boom may suddenly fall! For safety reasons, a raised boom must be secured against dropping before you pass or stand under it. q The boom must be secured against moving if any work is to be carried out under it when it is in a raised position.
  • Page 57 If any loose bolts are found, stop work and tighten to the specified torque. q If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. q Replace all hoses every 2 years at the latest. The shelf life of the hose should not exceed 2 years.
  • Page 58 SAFETY PRECAUTIONS FOR MAINTENANCE WASTE MATERIALS To prevent pollution, pay careful attention to the method of disposing of waste materials. q Always put oil drained from your machine in containers. Never drain oil directly onto the ground or dump into the sewage system, rivers, the sea, or lakes.

  • Page 59: Precautions With Tires

    The values for tyre pressure and permitted speed given in this manual correspond to the manufacturers' values. See also "HANDLING THE TIRES (3-99)". q For details, please refer to your Komatsu distributor or the tyre manufacturer. PRECAUTIONS WHEN STORING TIRES Tires for construction equipment are extremely heavy, so they may cause serious personal injury.

  • Page 60: Operation

    OPERATION...

  • Page 61: General View

    OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE (1) Bucket (8) Turn signal lamp (2) Tilt lever (9) Head lamp (3) Front wheel (10) Lift cylinder (4) Bucket cylinder (11) Lift arm (5) Front working lamp (12) Rear working lamp (6) ROPS cab (13) Rear combination lamp (7) Rear wheel...

  • Page 62: General View Of Controls And Gauges

    OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES (1) Parking brake lever (15) Lift arm control lever (2) Rear wiper switch (16) Directional selector switch (3) Front wiper switch (17) Variable shift control switch (4) Front working lamp switch (18) Speed range selector switch (5) Rear working lamp switch (19) Starting switch...
  • Page 63 OPERATION GENERAL VIEW MACHINE MONITOR (1) Pilot lamp for speed range selector switch position (14) Parking brake reminder caution lamp (2) Steering oil pressure caution lamp (15) Axle oil temperature caution lamp (3) Emergency steering pilot lamp (16) Engine oil level caution lamp (4) Preheating pilot lamp (17) Air cleaner clogging caution lamp (5) Directional lever position pilot lamp...

  • Page 64: Explanation Of Components

    OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays. MACHINE MONITOR A: Character display E: Pilot display...

  • Page 65: Monitor System

    Lamps (2) go out after the engine starts. If any lamps do not light up there is probably a failure or a disconnection, so please ask your Komatsu distributor to carry out inspection. q When the starting switch is turned ON, if the directional lever is not at the neutral position, the central warning lamp lights up and the alarm buzzer sounds intermittently.

  • Page 66: Types Of Warning

    OPERATION EXPLANATION OF COMPONENTS TYPES OF WARNING If an abnormality occurs on the machine, or if any switch or lever is operated accidently, the monitor display and buzzer give a warning to inform the operator. Following are the types of warning depending on the level of danger.

  • Page 67: Character Display Portion

    OPERATION EXPLANATION OF COMPONENTS CHARACTER DISPLAY PORTION (1) Service meter (4) Filter, oil replacement time display (2) Action code display (3) Failure code display Normally, the service meter is displayed on the character display. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed to recommend suitable action.
  • Page 68 If action code E03 is displayed, stop the machine immediately and check the failure code. For details, see “FAILURE CODE DISPLAY (3-11)“. Inform your Komatsu distributor of the failure code and ask for repairs. If there is a failure on the machine, or it is necessary to change the method of operation, or if inspection or mainte- nance must be carried out, action code E00, E01, E02, or E03 is displayed on the character display in display por- tion.
  • Page 69 OPERATION EXPLANATION OF COMPONENTS E01: When a failure occurs in the mechanical system, such as a drop in the level of the engine cooling water, the maintenance location is displayed. If the maintenance caution lamp lights up at the same time, carry out inspection and maintenance of the item indicated after completion of the day's work or when changing shifts.
  • Page 70 If an action code is displayed on the character display, check the failure code according to the failure code display method given below. When contacting your Komatsu distributor to request repairs, please inform your distributor of the failure code. Method of displaying failure code 1.
  • Page 71 OPERATION EXPLANATION OF COMPONENTS FILTER, OIL REPLACEMENT TIME DISPLAY After completion of the system check and when the starting switch is in the ON position, if any filter or oil item is approach- ing the replacement time, this display (4) shows the item for approx.
  • Page 72 OPERATION EXPLANATION OF COMPONENTS REMARK See the section below for details of the procedure for replacing the filter and oil. Engine oil “CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (4-48)“ Engine oil filter “CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (4-48)“ Fuel filter “REPLACE FUEL FILTER CARTRIDGE (4-49)“...

  • Page 73: Emergency Stop Item

    OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEM CAUTION If these lamps light up and the buzzer sounds, stop operations immediately and carry out inspection and maintenance of the applicable location. If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the lamp for the location of the abnormality and the central warning lamp will light up.
  • Page 74 OPERATION EXPLANATION OF COMPONENTS If the brake oil pressure caution lamp lights up, the footbrake may not work, so keep the parking brake applied to prevent the machine from moving. Keep the parking brake applied to prevent the machine from moving until the brake pressure becomes normal and the brake oil pressure caution lamp goes out.

  • Page 75: Caution Items

    OPERATION EXPLANATION OF COMPONENTS If the steering oil pressure goes down during operation, the steering oil pressure caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, “E03 CALL“ and “CHECK RIGHT NOW“ are displayed on the character display in turn, so stop the machine immediately in a safe place, then stop the engine and carry out inspection.
  • Page 76 OPERATION EXPLANATION OF COMPONENTS lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, “E02“ and “BRAKE OVERHEAT“ are displayed on the character display in turn, so take the fol- lowing action. 1. Release the accelerator pedal and move the speed range selector switch down one range to reduce the travel speed.

  • Page 77: Warning/Limit Functions For Travel Speed

    OPERATION EXPLANATION OF COMPONENTS ENGINE COOLING WATER TEMPERATURE CAUTION LAMP This lamp (4) lights up to warn the operator that the engine cooling water temperature has risen. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up.

  • Page 78: Inspection And Maintenance Item

    OPERATION EXPLANATION OF COMPONENTS INSPECTION AND MAINTENANCE ITEM CAUTION If these lamps light up, stop operations quickly and carry out the following action. (1) Radiator water level caution lamp (4) HST oil filter clogging caution lamp (2) Engine oil level caution lamp (5) Air cleaner clogging caution lamp (3) Maintenance caution lamp RADIATOR COOLANT LEVEL CAUTION LAMP...
  • Page 79 OPERATION EXPLANATION OF COMPONENTS 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. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor lights up if the oil level in the engine oil pan is low.
  • Page 80 OPERATION EXPLANATION OF COMPONENTS AIR CLEANER CLOGGING CAUTION LAMP This lamp (5) lights up if the air cleaner element becomes clogged when the engine is running. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up.

  • Page 81: Pilot Display Portion

    OPERATION EXPLANATION OF COMPONENTS 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 (5) Pilot lamp for speed range selector switch position (2) Preheating pilot lamp (6) Turn signal pilot lamp (3) Emergency steering pilot lamp (7) Head lamp high beam pilot lamp...
  • Page 82 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STEERING PILOT LAMP (Green) If this lamp (3) lights up when the engine is running or when the machine is operating, it indicates that the condition is normal. If it does not light up, an abnormality has occurred in the emer- gency steering circuit.
  • Page 83 OPERATION EXPLANATION OF COMPONENTS HEAD LAMP HIGH BEAM PILOT LAMP This lamp (7) lights up when the head lamp is at high beam. 3-24...

  • Page 84: Meter Display Portion

    OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION (1) HST oil temperature gauge (4) Speedometer (2) Engine cooling water temperature gauge (5) Meter display pilot lamp (3) Fuel gauge HST OIL TEMPERATURE GAUGE This meter (1) indicates the HST oil temperature. During normal operations, the indicator should be in the white range (A).
  • Page 85 OPERATION EXPLANATION OF COMPONENTS FUEL GAUGE This meter (3) indicates the amount of fuel remaining in the fuel tank. If the indicator is at the F position, it indicates that the tank is full. If the indicator is at the E position, it indicates that there is little fuel remaining.

  • Page 86: Other Functions Of Machine Monitor

    OPERATION EXPLANATION OF COMPONENTS OTHER FUNCTIONS OF MACHINE MONITOR The machine monitor also has the following functions. Odometer, filter/oil replacement time reset, language selection, HST selector function METHOD OF DISPLAYING ODOMETER Use this when checking the total distance that the machine has traveled. 1.
  • Page 87 OPERATION EXPLANATION OF COMPONENTS 5. Press the ( ) of monitor mode selector switch 1. [RESET] and [YES <> NO] are displayed in turn. 6. When resetting the replacement time, press (>) or (<) of monitor panel mode selector switch 2, align the cursor with “YES“, then press ( ) of machine monitor mode selector switch 1.
  • Page 88 OPERATION EXPLANATION OF COMPONENTS METHOD OF SELECTING HST CHANGING FUNCTION When the speed range selector switch is in 3rd or 4th position, there are two selections available for the HST. Use this when changing the selection. Speed range selector switch position Function 3rd position 4th position...

  • Page 89: Switches

    OPERATION EXPLANATION OF COMPONENTS SWITCHES (1) Starting switch (10) Hazard lamp switch (2) Speed range selector switch (11) Front working lamp switch (3) Variable shift control switch (12) Rear working lamp switch (4) Directional selector switch (13) Monitor panel mode selector swiitch 1 (5) Directional selector actuation switch (14) Monitor panel mode selector swiitch 2 (6) Traction control switch...
  • Page 90 OPERATION EXPLANATION OF COMPONENTS START position This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately after the engine has been started. The key will return to the ON position when released. SPEED RANGE SELECTOR SWITCH Use this switch (2) to switch the speed range.
  • Page 91 OPERATION EXPLANATION OF COMPONENTS DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH When this switch (5) is turned on, the directional selector switch is actuated. Position (a): ON The directional selector switch is actuated. Position (b): OFF The directional selector switch is turned off. REMARK Turn this switch ON when the directional lever and directional selector switch are at the neutral position.
  • Page 92 OPERATION EXPLANATION OF COMPONENTS E.C.S.S. SWITCH (Option) WARNING q If the machine is traveling or the work equipment is raised, the moment the E.C.S.S. switch is turned ON, the work equipment will move. q If the E.C.S.S. system is switched on, the work equipment may move. q Never turn the E.C.S.S.
  • Page 93 OPERATION EXPLANATION OF COMPONENTS LAMP SWITCH This switch (8) is used to light up the front lamps, side clear- ance lamps, tail lamps, and instrument panel. Position (a): OFF (Lamps go out) Position (b): Side clearance lamps, tail lamps, and instrument panel light up Position (c): Head lamps light up in addition to lamps at (b) position...
  • Page 94 OPERATION EXPLANATION OF COMPONENTS HORN BUTTON When the horn button (9) in the center of the steering wheel is pressed, the horn will sound. HAZARD LAMP SWITCH WARNING Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for other machine operators.
  • Page 95 OPERATION EXPLANATION OF COMPONENTS REAR WORKING LAMP SWITCH WARNING Always turn the working lamp off before traveling on public roads. This switch (12) is used to light up the rear working lamp. Position (a): Working lamp and pilot lamp (A) light up Position (b): Working lamp goes out REMARK If the lamp switch is not at the ON position for the side clear-...
  • Page 96 OPERATION EXPLANATION OF COMPONENTS FRONT WIPER SWITCH When rotary switch (A) of this switch (15) is turned, the front wiper will move. If push button (B) is pressed, washer liquid will be sprayed out onto the front glass while the button is being pressed. Position (a): (OFF) Stop Position (b): (INT) Intermittent wiper Position (c): Low-speed wiper...
  • Page 97 OPERATION EXPLANATION OF COMPONENTS ROOM LAMP SWITCH The switch (18) is used to turn the room lamp ON and OFF. Position (a): OFF Position (b): Lights up when the cab door opens Position (c): Lights up REMARK The room lamp lights up even when the main switch is OFF, so when leaving the operator's compartment, turn the switch to position (a) (OFF) or (b).

  • Page 98: Control Levers, Pedals

    OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS, PEDALS (1) Directional lever (5) Brake pedal (2) Safety lock lever (for work equipment lever) (6) Accelerator pedal (3) Lift arm control lever (7) Parking brake lever (4) Bucket control lever DIRECTIONAL LEVER This lever (1) is used to switch the direction of travel of the machine between forward and reverse.
  • Page 99 OPERATION EXPLANATION OF COMPONENTS SAFETY LOCK LEVER (FOR WORK EQUIPMENT LEVER) WARNING q Before leaving the operator's seat, set the safety lock lever securely to the LOCK position. If the safety lock lever is not at the LOCK position, and work equipment control lever is touched by mistake, it may lead to a serious accident.
  • Page 100 OPERATION EXPLANATION OF COMPONENTS BUCKET CONTROL LEVER This lever (4) operates the bucket. Position (a): TILT When the bucket control lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset posi- tion of the positioner, and the lever is returned to the HOLD position.
  • Page 101 If the parking brake has been used as an emergency brake when traveling at high speed (near the max- imum speed), contact your Komatsu distributor to have the parking brake checked for any abnormal- ity.

  • Page 102: Steering Tilt Lock Lever

    OPERATION EXPLANATION OF COMPONENTS 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 allows the steering column to be tilted forward or backward.

  • Page 103: Safety Bar

    OPERATION EXPLANATION OF COMPONENTS METHOD OF OPENING AND CLOSING COVER WITH LOCK (ENGINE SIDE COVER) TO OPEN THE COVER 1. Insert the key into the key slot. 2. Turn the key counterclockwise and open the cover by pull- ing the cover grip. TO LOCK THE COVER 1.

  • Page 104: Towing Pin

    OPERATION EXPLANATION OF COMPONENTS TOWING PIN 1. Align protrusion (1) in the towing pin with groove (2) in the counterweight, then insert the pin and turn it 180°. 2. To prevent the towing pin from turning, fold the handle of the towing pin and set it in position.

  • Page 105: Cab Door Open Lock

    OPERATION EXPLANATION OF COMPONENTS 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.

  • Page 106: Fuse Capacity And Name Of Circuit

    OPERATION EXPLANATION OF COMPONENTS FUSE CAPACITY AND NAME OF CIRCUIT FUSE BOX A No. Fuse capacity Name of circuit Starting switch Hazard warning flashing lamp HST control A Parking brake A Instrument panel Radio A, Room lamp Auxiliary pwe (Battery +24V) Head Lamp L.H.

  • Page 107: Slow Blow Fuse

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

  • Page 108: Air Conditioner

    OPERATION EXPLANATION OF COMPONENTS 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 pos- sible to provide a pleasant working environment even on dusty jobsites. GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL (1) Fan switch (4) FRESH/RECIRC switch...
  • Page 109 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH This switch (2) is used to start or stop the cooling or dehumidi- fying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.
  • Page 110 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH The temperature can be adjusted with this switch (5) by press- ing and holding the up or down button. The temperature level indicator lamps (A) light up to display the temperature of the air coming from the vents. The more blue lamps on, the lower the temperature is.

  • Page 111: Method Of Operation

    OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION Switchs Air conditioner Temperature FRESH/RECIRC Mode selector Fan switch switch control switch selector switch switch Condition of use Rapid All blue RECIRC FACE Cooling More than half Normal HI-LO FRESH FACE are blue Dehumidifying, More than half HI-LO...

  • Page 112: Precautions When Using

    OPERATION EXPLANATION OF COMPONENTS COOL BOX When the cooling is being used, this can be used for keeping drinks and other things cool. When the heating is being used, it can be used to keep things warm. When using the box, open the vent grill (1). When not using the box, close the grill (1).

  • Page 113: Operation

    Leakage of fuel or oil will cause the machine to catch fire. Check carefully, and be sure to repair any abnormalities, or please contact your Komatsu distributor. Always carry out the items in this section before starting the engine each day.
  • Page 114 OPERATION OPERATION 7. Check for damage and loose bolts on handrail and steps. Repair any damage and tighten any loose bolts. 8. Check the fill level of the grease container of the central lubrication system (optional). Refill grease if required. On the display of the lubrication pump, check that there is no error message.
  • Page 115 OPERATION OPERATION 14. Inspect tires. WARNING If worn or damaged tires are used, they may burst and cause serious injury or death. To ensure safety, do not use the following tires. Wear: Tires with a tread groove of less than 15% of that of a new tire Tires with extreme uneven wear or with stepped-type wear Damage:...

  • Page 116: Check Before Starting

    OPERATION OPERATION CHECK BEFORE STARTING Always carry out the items in this section before starting the engine each day. CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns.
  • Page 117 OPERATION OPERATION CHECK WATER SEPARATOR The water separator separates water mixed in the fuel. If float (2) goes above water drain line (2), drain the water as follows. 1. Loosen drain plug (3) and drain the accumulated water until the float (1) reaches the bottom. 2.
  • Page 118 OPERATION OPERATION CHECK COOLANT LEVEL, ADD COOLANT WARNING q Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank. q Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
  • Page 119 If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause and make the repair. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.
  • Page 120 CHECK PARKING BRAKE Check that the parking brake works properly. If there is any abnormality in the operation of the parking brake or the brake does not provide the proper braking effect, please contact your Komatsu distributor for adjustment. 3-61...
  • Page 121 OPERATION OPERATION CHECK BRAKE PEDAL Drive the machine forward and check the effect of the brakes. If there is any abnormality in the actuation of the brakes, please contact your Komatsu distributor to have the brakes adjusted. 3-62...

  • Page 122: Adjustment

    OPERATION OPERATION ADJUSTMENT SEAT ADJUSTMENT WARNING When adjusting the position of the operator's seat, always set the safety lock lever to the LOCK position to prevent any accidental contact to the control levers. q Always adjust the operator's seat before starting each operation or when the operators change shift. q When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
  • Page 123 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. Amount of adjustment: 60 mm (2.4 in) (E) Setting seat for weight Sit on the seat, raise your body slightly, then operate switch (5) to adjust the strength of the suspension. Amount of adjustment: 50 - 130 kg (110 - 287 lb)(target) When + is pressed: Suspension becomes stronger When - is pressed: Suspension becomes weaker...
  • Page 124 OPERATION OPERATION (J) Lumbar support Operate switch (8) to give a suitable tension to the lower lumbar region. Operate switch (9) to give a suitable tension to the upper lumbar region. When + is pressed: Tension becomes stronger When - is pressed: Tension becomes weaker (K) Side support Operate switch (10) to give a suitable tension to the left and right lumbar region.
  • Page 125 OPERATION OPERATION ADJUST SEAT BELT Always wear the seat belt. WARNING q Before fastening the seat belt, check that there is no abnormality in the belt mounting bracket or mounting belt. If the belt is worn or damaged, replace it. q Fasten the seat belt before starting operations.
  • Page 126 OPERATION OPERATION ADJUST LEVER STAND Adjust height of wrist rest Loosen lock lever (2) and adjust the height of wrist rest (1). Amount of adjustment: 60 mm (2.4 in) REMARK Keep button (3) pressed and operate lock lever (2) to the FREE position.

  • Page 127: Operations And Checks Before Starting Engine

    OPERATION OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING Before starting the engine, check that the safety lock lever is securely at the LOCK position. If the work equipment control lever is touched by accident when starting the engine, the work equipment may move unexpectedly and cause serious damage or personal injury.
  • Page 128 3 seconds, and the alarm buzzer sounds for approx. 1 sec. If any monitor does not light up, there is probably a failure or disconnection, so contact your Komatsu distributor for inspection. 3-69...

  • Page 129: Starting Engine

    OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING q Start the engine only after sitting down in the opera- tor's seat. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause seri- ous bodily injury or fire.
  • Page 130 OPERATION OPERATION 2. Depress accelerator pedal (3) lightly. 3. After the preheating pilot lamp (2) goes out, turn the key of starting switch (1) to the START position to start the engine. 4. After the engine starts, release the key in starting switch (1).

  • Page 131: Starting In Cold Weather

    OPERATION OPERATION STARTING IN COLD WEATHER WARNING q Start the engine only after sitting down in the opera- tor's seat. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause seri- ous bodily injury or fire.
  • Page 132 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.

  • Page 133: Operations And Checks After Starting Engine

    There is danger that the pump may be broken. 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.

  • Page 134: Normal Operation

    OPERATION OPERATION NORMAL OPERATION After starting the engine, do not immediately start operations. First, carry out the following operations and checks. NOTICE Do not suddenly accelerate the engine before the warm- ing-up operation is completed. Do not run the engine at low idling or high idling continu- ously for more than 20 minutes.

  • Page 135: Stopping Engine

    (5) are in the white range. 6. Check that there is no abnormal exhaust gas color, noise or vibration. If any abnormality is found, contact your Komatsu distributor. STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened.

  • Page 136: Moving The Machine

    OPERATION OPERATION MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE3 WARNING q Always remove the safety bar for travel operations. If it is not removed, the steering wheel cannot be used for steering, and this may lead to serious damage or injury. q When moving the machine, check that the area around the machine is safe, then sound the horn before starting.
  • Page 137 Check that the backup alarm sounds when the direc- tional lever is set to REVERSE. If the backup alarm does not sound, please contact your Komatsu distribu- tor for repairs. 7. Release brake pedal (4), then depress accelerator pedal (8) to move the machine.

  • Page 138: Changing Direction

    Position (b): REVERSE q Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does not sound, please contact your Komatsu distributor for repairs. USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE...
  • Page 139 OPERATION OPERATION 2. Place the directional selector switch (2) at the N position. 3. Place the directional selector switch actuation switch (3) at the ON position (a). 4. Place the directional selector switch (2) at the F (forward) or R (reverse) position. REMARK When the directional selector switch actuation switch (3) is at the ON position, if the directional lever (1) is oper- ated to FORWARD or REVERSE, the machine will travel in forward or reverse according to the operation of the...

  • Page 140: Stopping The Machine

    OPERATION OPERATION STOPPING THE MACHINE WARNING q Avoid stopping suddenly. Give yourself ample room when stopping. q Even if the parking brake lever is pulled and set to the LOCK position, there is a danger of the machine mov- ing until the parking brake pilot lamp lights up, so keep the brake pedal depressed.

  • Page 141: Turning

    Check that there is a play of 50 to 100 mm (2.0 to 3.9 in) in the steering wheel. Check also that the steering works properly. If any abnormality is found, please contact your Komatsu distributor for inspection. 3-82...

  • Page 142: Emergency Steering

    OPERATION OPERATION EMERGENCY STEERING CAUTION Never actuate the emergency steering except during emergencies or when checking the function. When using the emergency steering, travel at a speed of less than 5 km/h (3.1 MPH). Emergency steering pilot lamp (green) (2) lights up to inform the operator that the emergency steering system is normal.

  • Page 143: Operation Of Work Equipment

    OPERATION OPERATION OPERATION OF WORK EQUIPMENT WARNING Never raise the boom with the bucket fully loaded when the machine is articulated. There is danger that the machine may tip over. Lift arm control lever (1) and bucket control lever (2) can be used to operate the lift arm and bucket as follows.
  • Page 144 OPERATION OPERATION BUCKET OPERATION Position (a): TILT When the bucket control lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position.

  • Page 145: Work Possible Using Wheel Loader

    OPERATION OPERATION WORK POSSIBLE USING WHEEL LOADER In addition to the following, it is possible to further increase the range of applications by using various attachments. DIGGING OPERATIONS WARNING q Never carry out digging or scooping operations with the machine articulated. There is danger that the machine may tip over.
  • Page 146 OPERATION OPERATION 3. When the material is in a stockpile,keep the cutting edge of the bucket horizontal; when loading blasted rock, have the bucket tilting slightly down. Be careful not to get blasted rock under the bucket. This will make the front tires come off the ground and slip. Try to keep the load in the center of the bucket;...
  • Page 147 OPERATION OPERATION 6. If there is too much material loaded in the bucket, dump and tilt the bucket quickly to remove the excessive load. This prevents spillage of the load during hauling. DIGGING AND LOADING ON LEVEL GROUND q When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the machine forward.

  • Page 148: Leveling Operations

    OPERATION OPERATION LEVELING OPERATIONS q Always operate the machine in reverse when carrying NOTICE out leveling operations. If it is necessary to carry out leveling operations when traveling forward, do not set the bucket dumping angle to more than 20 degrees. q Turn the E.C.S.S.

  • Page 149: Loading Operations

    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 q Always keep the jobsite flat, and do not operate the steering wheel suddenly or apply the brakes sud- denly when the lift arm is raised with a loaded bucket.
  • Page 150 OPERATION OPERATION V-SHAPE LOADING Position the dump truck so that the direction of approach of the wheel loader is approx. 60 degrees from the direction of approach to the stockpile. After loading the bucket, drive the wheel loader in reverse, then turn it to face the dump truck and travel forward to load the dump truck.

  • Page 151: Precautions For Operation

    If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine. NOTICE If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the parking brake checked for any abnormality.
  • Page 152 The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface. Contact your Komatsu distributor or tire dealer for information. q The following is a guide to suitable tire pressures and speeds when traveling on a paved surface with standard tires.

  • Page 153: Adjusting Work Equipment Posture

    OPERATION OPERATION ADJUSTING WORK EQUIPMENT POSTURE WARNING q Stop the machine on flat ground and put blocks in front and behind the wheels. q Set parking brake lever to the LOCK position. q Secure the front and rear frames with the safety bar. q Always attach the warning tag to the work equipment control lever.

  • Page 154: Adjusting Bucket Positioner

    OPERATION OPERATION ADJUSTING BUCKET POSITIONER 1. Lower the bucket to the ground, set to the desired digging angle, return the bucket control lever at HOLD, then set the safety lever to the LOCK position and stop the engine. 2. Loosen 2 bolts (1), adjust the position of mounting bracket (4) of the proximity switch so that the rear tip of bar (2) is in line with the center of the sensing surface of proximity switch (3), then tighten bolts to hold the bracket in position.

  • Page 155: Parking Machine

    OPERATION OPERATION PARKING MACHINE WARNING q Avoid stopping suddenly. Give yourself ample room when stopping. q Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.

  • Page 156: Check After Stopping Engine

    OPERATION OPERATION 3. Pull parking brake lever (4) and set it to the LOCK position. 4. Operate lift arm control lever (5) to lower the bucket to the ground. 5. Check that the work equipment control lever is at the HOLD position, then set safety lock lever (6) to the LOCK position.

  • Page 157: Locking

    OPERATION OPERATION LOCKING Always lock the following parts. (1) Fuel filler cap (2) Rear grill (3) Engine side cover (2 places) (4) Cab door (2 places) REMARK The starting switch key is used also for locks (1), (2), (3) and (4).

  • Page 158: Handling The Tires

    Bead AE40786B-A Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. TIRE PRESSURE Measure the tire pressure before starting operations, when the tires are cool.

  • Page 159: Precautions For Using Load And Carry Method

    When traveling continuously with load and carry operations, choose the correct tires to match the operating condi- tions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged, so con- tact your Komatsu distributor or tire dealer when selecting tires. 3-100...

  • Page 160: Transportation

    OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION PROCEDURE As a basic rule, always transport the machine on a trailer. When selecting the trailer, see the weights and dimensions given in Section “TECHNICAL DATA (5-2)“. Note that the specifications for the weights and dimensions for transportation differ according to the type of tires and type of bucket.

  • Page 161: Securing Machine

    OPERATION TRANSPORTATION 2. Apply the brakes on the trailer securely and insert blocks under the tires to ensure that the trailer does not move. Then fix the ramps in line with the centers of the trailer and the machine. Ramp Be sure that the two sides are at the same height as one another.

  • Page 162: Unloading

    OPERATION TRANSPORTATION UNLOADING 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the brakes on the trailer securely and insert blocks under the tires to ensure that the trailer does not move. Then fix the ramps in line with the centers of the trailer and the machine.

  • Page 163: Lifting Machine

    Never go under the machine when it is raised. CAUTION When the machine is raised, check that there is no oil leakage from the hydraulic circuits. When carrying out the lifting operation, please contact your Komatsu distributor. NOTICE The lifting procedure applies to machines with standard specifications.

  • Page 164: Location Of Lifting Position Mark

    There is a serious danger that the machine will lose its balance. WEIGHT TABLE Machine weight Front wheel load Rear wheel load Center of gravity WA320-5H 13660 kg (30120 lb) 6060 kg (13362 lb) 7600 kg (16758 lb) 1690 mm (5 ft 7 in) 3-105...

  • Page 165: Lifting Procedure

    When the machine is raised, check that there is no oil leakage from the hydraulic circuits. When carrying out the lifting operation, please contact your Komatsu distributor. Lifting work can be carried out only for machines with lifting marks. Before starting the lifting operation, stop the machine in a horizontal place and do as follows.

  • Page 166: Cold Weather Operation

    When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor. Antifreeze is toxic, so do not let it flow into drainage ditches or spray it on to the ground surface.

  • Page 167: Battery

    OPERATION COLD WEATHER OPERATION BATTERY WARNING q The battery generates flammable gas, so do not bring fire or sparks near the battery. q Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.

  • Page 168: After Cold Weather

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

  • Page 169: Long-Term Storage

    NOTICE If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu distributor. When using the machine after long-term storage, do as follows before using it. q Wipe off the grease from the hydraulic cylinder rods.

  • Page 170: Troubleshooting

    The machine must not be towed for long distances. q For details of the procedure for towing a machine when it has broken down, please contact your Komatsu distributor. This machine must not be towed except in emergencies. When towing the machine, take the following precau- tions.

  • Page 171: When Engine Can Be Used

    OPERATION TROUBLESHOOTING q If the machine is moved suddenly, the tow rope or bar will be subjected to an excessive load, and it may break. Start the machine gradually and travel at a constant speed. q The towing machine should normally be of the same class as the machine being towed. Check that the towing machine has ample braking power, weight, and rimpull to allow it to control both machines on slopes or on the tow road.

  • Page 172: If Battery Is Discharged

    OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING q When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. q The battery generates hydrogen gas, so there is a haz- ard of explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks.

  • Page 173: Precautions For Charging Battery

    OPERATION TROUBLESHOOTING PRECAUTIONS FOR CHARGING BATTERY When charging the battery, if the battery is not handled cor- rectly, there is danger that the battery may explode. Always follow the instructions in “BATTERY (3-108)“ and the instruc- tion manual accompanying the charger, and do as follows. q Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line.

  • Page 174: Starting Engine With Booster Cable

    OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING q When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. q When starting the engine with a booster cable, always wear safety glasses and rubber gloves.
  • Page 175 OPERATION TROUBLESHOOTING STARTING ENGINE WARNING Always check that the safety lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are at the HOLD or neutral position. 1.

  • Page 176: Other Trouble

    OPERATION TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ): Always contact your Komatsu distributor when dealing with these items. q In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even •Defective wiring...

  • Page 177: Chassis

    OPERATION TROUBLESHOOTING CHASSIS ): Always contact your Komatsu distributor when dealing with these items. q In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine is running but machine •Parking brake is applied...
  • Page 178 OPERATION TROUBLESHOOTING Problem Main causes Remedy Hydraulic system Bucket lacks lifting power •Lack of oil •Add oil to specified level. See EVERY 100 HOURS Bucket takes time to go up •Clogged hydraulic filter •Replace cartridge, see EVERY 2000 HOURS SERVICE Excessive bubbles in oil •Replace with good quality oil •Poor quality oil...

  • Page 179: Engine

    OPERATION TROUBLESHOOTING ENGINE ): Always contact your Komatsu distributor when dealing with these items. q In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure caution pilot •Add oil to specified level, see...
  • Page 180 OPERATION TROUBLESHOOTING Problem Main causes Remedy Abnormal noise generated (com- •Low grade fuel being used •Change to specified fuel bustion or mechanical) •Overheating •Refer to “Water temperature gauge is in red range“ as above •Damage inside muffler (•Replace muffler) •Excessive valve clearance (•Adjust valve clearance) 3-121...
  • Page 181 OPERATION TROUBLESHOOTING 3-122...

  • Page 182: Maintenance

    MAINTENANCE...

  • Page 183: Guides To Maintenance

    KOMATSU GENUINE REPLACEMENT PARTS: Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE OILS: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem- perature. ALWAYS USE CLEAN WASHER FLUID: Use automobile window washer fluid, and be careful not to let any dirt get into it.
  • Page 184 MAINTENANCE GUIDES TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: q Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged. q Clean the radiator core frequently to avoid clogging. q Clean and replace the fuel filter frequently. q Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.

  • Page 185: Outlines Of Service

    When changing the oil, always replace the related filters at the same time. q We recommend you have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor. FUEL q The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.

  • Page 186: Coolant

    Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts. CARRYING OUT KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed.

  • Page 187: Storing Oil And Fuel

    Carry out sampling regularly at fixed intervals. q Do not carry out sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. STORING OIL AND FUEL q Keep indoors to prevent any water, dirt, or other impurities from getting in.

  • Page 188: Biodegradable Hydraulic Oil And Lubricants

    BIODEGRADABLE HYDRAULIC OIL AND LUBRICANTS The use of biodegradable hydraulic oils and lubricants - on the basis of synthetic esters - for Komatsu machines is permitted. For information on the products cleared for use and best suited for your application contact our autho- rized service workshops.

  • Page 189: Wear Parts

    When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.

  • Page 190: Fuel, Coolant And Lubricants

    MAINTENANCE FUEL, COOLANT AND LUBRICANTS FUEL, COOLANT AND LUBRICANTS LUBRICATION CHART WA320-5gb-oilchart-2 1. Lubrication intervals are based on the service meter reading. 2. Abbreviations: EO = Engine Oil, G = Lithium Grease No. 2, F = Diesel Fuel, AXO = Axle Oil, HO = Hydraulic Oil. 3.

  • Page 191: Proper Selection Of Fuel, Coolant And Lubricants

    *** North American manufacted DONAX TD 20W-40 must not be used. **** North American manufacted TORQUE FLUID 56 must not be used. (1): Please use SAE10W30 for the oil in the hydraulic system. If Komatsu genuine oil is not available, select the oil from the table below.
  • Page 192 MAINTENANCE FUEL, COOLANT AND LUBRICANTS *2: For the standard differential, except for “AXO80“, the oil for machines equipped with the limited-slip differential in the table below and E030 can be used. However, in the case of “E030“, depending on conditions such as the way the brakes are used and the oil temperature, the brakes may squeal just before the machine stops, but there is no problem with the brake performance or durability.
  • Page 193 There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add sin- gle grade oil that matches the temperature range in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
  • Page 194 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT(Winter, one EO15-40CD season type) Diesel sigma S super dieselmulti- AGIP Rotra MP GR MU/EP...
  • Page 195 MAINTENANCE FUEL, COOLANT AND LUBRICANTS Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.) Multi-purpose white *Superme duty Multi-purpose 4092...

  • Page 196: Standard Tightening Torques For Bolts And Nuts

    Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

  • Page 197: Periodic Replacement Of Safety Critical Parts

    When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the critical parts. Replacement inter- Safety critical parts for periodic replacement...

  • Page 198: Maintenance Schedule Chart

    MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) REPLACE HST OIL FILTER ELEMENT ......................4-534 REPLACE HYDRAULIC FILTER ELEMENT ....................4-554 WHEN REQUIRED CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT ................4-204 DUST PRE-EXTRACTOR "TURBO II": CHECK, CLEAN.................
  • Page 199 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 1000 HOURS SERVICE CHANGE OIL IN TRANSFER CASE ........................ 4-514 CLEAN TRANSFER CASE BREATHER ......................4-524 REPLACE HST OIL FILTER ELEMENT ......................4-534 LUBRICATING ..............................4-544 CHECK TIGHTENING PARTS OF TURBOCHARGER ..................4-544 CHECK PLAY OF TURBOCHARGER ROTOR ....................4-544 CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT .............

  • Page 200: Service Procedure

    MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE INITIAL 250 HOURS SERVICE Carry out the following maintenance only after the first 250 hours. q REPLACE HST FILTER ELEMENT q REPLACE HYDRAULIC FILTER ELEMENT For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS and 2000 HOURS SERVICE.

  • Page 201: When Required

    MAINTENANCE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT WARNING q If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. q When using compressed air, there is danger that dirt may be blown around and cause serious injury.
  • Page 202 MAINTENANCE SERVICE PROCEDURE 4. Clean the interior of the air cleaner body, cover (3) and evacuator valve (6). NOTICE The inner element must not be used again even after its cleaning. When replacing the inner element, replace the outer element at the same time. 5.

  • Page 203: Dust Pre-Extractor "Turbo Ii": Check, Clean

    MAINTENANCE SERVICE PROCEDURE REPLACING ELEMENT 1. Open the engine side cover on the right side of the machine. 2. Remove three clips (2), then remove cover (3). 3. Remove outer element (4). Do not remove inner element (5) at this time, however. 4.

  • Page 204: Clean Inside Of Cooling System

    30% by volume is necessary. In areas where the water is hard, always add Komatsu genuine corrosion resistor agent KI. One packet of corro- sion resistor (No. 600-411-1120) agent contains 100g (0.22 lb). The standard density of the mixture should be 7g/ liter (0.065 oz/US gal).
  • Page 205 If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once. Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.
  • Page 206 MAINTENANCE SERVICE PROCEDURE 5. Set a container in position to catch drained antifreeze mix- ture, then open valve (2) under the radiator to drain cooling water. 6. After draining the water, close drain valve (2) and fill with tap water. 7.

  • Page 207: Check Oil Level In Transfer Case, Add Oil

    MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN TRANSFER CASE, 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 transfer case.

  • Page 208: Check Axle Oil Level, Add Oil

    MAINTENANCE SERVICE PROCEDURE CHECK AXLE OIL LEVEL, ADD OIL WARNING q When checking the oil level, apply the parking brake and secure the front and rear frames with the safety bar. q After stopping the engine, the parts and oil are at a high temperature. Wait for the temperature to go down before starting the operation.

  • Page 209: Clean Axle Case Breather

    MAINTENANCE SERVICE PROCEDURE 3. Set the oil level gauge (G) as shown in the right diagram. 4. The oil level is correct when it is between the two lines pro- vided on the oil level gauge. If the oil level does not reach the lower line, add axle oil through filler port (F).

  • Page 210: Clean Air Conditioner Condenser

    MAINTENANCE SERVICE PROCEDURE CLEAN AIR CONDITIONER CONDENSER WARNING q Do not wash the condenser with a steam cleaner. There is danger that the condenser could overheat. q If high-pressure water hits your body directly or dirt is sent flying, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment.

  • Page 211: Clean Radiator Fins And Cooler Fins

    MAINTENANCE SERVICE PROCEDURE CLEAN RADIATOR FINS AND COOLER FINS WARNING q Never open the engine side cover when the engine is running. Stop the engine completely before starting the cleaning operation. q If compressed air, pressurized water, or steam hits your body directly, or causes dirt to fly, it may lead to personal injury.

  • Page 212: Clean Transfer Oil Cooler Fins

    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 checked for dirt or disconnections. 4-31...

  • Page 213: Replace Bolt On Cutting Edge

    MAINTENANCE SERVICE PROCEDURE REPLACE BOLT ON CUTTING EDGE WARNING It is extremely dangerous if the work equipment moves when carrying out the turning or replacement operation. Set the work equipment in a stable position, stop the engine, then set the safety lock lever securely to the LOCK position.

  • Page 214: Replace Bucket Teeth

    MAINTENANCE SERVICE PROCEDURE REPLACE BUCKET TEETH WARNING q If the pin is hit out with strong force, there is danger that the pin may fly out. Check that there is no one in the surrounding area. q There is danger of pieces flying during the replacement operation, so always wear protective clothing, such as safety glasses and gloves.

  • Page 215: Check Air Conditioner

    MAINTENANCE SERVICE PROCEDURE CHECK AIR CONDITIONER CHECK LEVEL OF REFRIGERANT (GAS) WARNING If the refrigerant of the conditioner system gets into your eyes or on your hands, it may cause loss of sight or frost- bite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit.

  • Page 216: Replace Slow Blow Fuse

    MAINTENANCE SERVICE PROCEDURE REPLACE SLOW BLOW FUSE q Always turn the power OFF when replacing the slow NOTICE blow fuse (turn the starting switch to the OFF posi- tion). q Always replace the slow blow fuse with a fuse of the same capacity.

  • Page 217: Selection And Inspection Of Tires

    Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the fol- lowing table. Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when using optional tires.
  • Page 218 MAINTENANCE SERVICE PROCEDURE CHECK INFLATION PRESSURE OF TIRES WARNING When inflating a tire, check that no one will enter the work- ing area. Use an air chuck which has a clip and which can be fixed to the air valve. While inflating the tire, check the inflation pressure occa- sionally so that it will not rise too high.

  • Page 219: Check Before Starting

    MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For the following items, see “CHECK BEFORE STARTING (3-57)“. q Check oil level in engine oil pan, add oil q Check water separator q Check coolant level, add water q Check inflation pressure of tires q Check electric wiring q Check monitor panel q Check fuel level, add fuel...

  • Page 220: Every 50 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE DRAIN WATER, SEDIMENT FROM FUEL TANK Loosen valve (1) on the left side of the tank so that the sedi- ment and water will be drained together with fuel. 4-39...

  • Page 221: Every 100 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 100 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATE REAR AXLE PIVOT PIN (3 places) 1. Using a grease pump, pump in grease through the grease fittings marked by the arrows. 2.

  • Page 222: Check Oil Level In Hydraulic Tank, Add Oil

    MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING q The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

  • Page 223: Every 250 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE Maintenance for every 50 and 100 hours service should be carried out at the same time. CHECK BATTERY ELECTROLYTE LEVEL Carry out this check before operating the machine. WARNING q Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will acceler- ate deterioration of the inside of the battery and reduce the service life of the battery.
  • Page 224 Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER LEVEL line on the side of the battery, check as follows.

  • Page 225: Check Parking Brake

    If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level, follow the instructions given.

  • Page 226: Check For Loose Wheel Hub Bolts, Tighten

    NOTICE check that the V-belt is not touching the bottom of the V-groove. q In case any of the following occurs, ask the Komatsu distributor in your territory to replace the belts with new ones. 〈 The fan belt has elongated, leaving little allowance for adjustment.

  • Page 227: Clean Element In Air Conditioner Recirculation Filter

    MAINTENANCE SERVICE PROCEDURE 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.
  • Page 228 MAINTENANCE SERVICE PROCEDURE (3) Dump cylinder pin (2 places) (4) Lift cylinder pin (4 places) (5) Lift arm pivot pin (2 places) (6) Tilt lever pin (1 place) (7) Steering cylinder pin (4 places) 4-47...

  • Page 229: Every 500 Hours Service

    4. Loosen drain plug (P) and drain the oil. Be careful not to get oil on yourself. 5. Check the drained oil, and if there are excessive metal par- ticles or foreign material, please contact your Komatsu dis- tributor. 6. Tighten drain plug (P).

  • Page 230: Replace Fuel Filter Cartridge

    MAINTENANCE SERVICE PROCEDURE REPLACE FUEL FILTER CARTRIDGE WARNING q Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter. q Do not bring fire or sparks near the fuel. REMARK If the machine has run out of fuel, use Steps 3 to 10 to bleed the air.

  • Page 231: Clean Water Separator Strainer

    MAINTENANCE SERVICE PROCEDURE CLEAN WATER SEPARATOR STRAINER WARNING q Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter. q Do not bring fire or sparks near the fuel. 1.

  • Page 232: Every 1000 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Maintenance for every 50, 100, 250 and 500 hours service should be carried out at the same time. CHANGE OIL IN TRANSFER CASE WARNING q The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.

  • Page 233: Clean Transfer Case Breather

    MAINTENANCE SERVICE PROCEDURE CLEAN TRANSFER CASE BREATHER 1. Remove cover (1). 2. Remove the mud and dirt from around the breather (2), then remove breather (2). After removing the breather, take steps to prevent dirt or dust from entering the mount. 3.

  • Page 234: Replace Hst Oil Filter Element

    MAINTENANCE SERVICE PROCEDURE REPLACE HST OIL FILTER ELEMENT WARNING q The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.

  • Page 235: Lubricating

    Please contact your Komatsu distributor to have the rotor play checked. CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT Since inspection and replacement of the fan belt require special tools, contact your Komatsu distributor. REMARK The machine is equipped with an auto tensioner, so there is no need to adjust the tension.

  • Page 236: Every 2000 Hours Service

    MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT WARNING q The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.

  • Page 237: Replace Hydraulic Tank Breather Element

    MAINTENANCE SERVICE PROCEDURE 13. Check the hydraulic oil level and add oil to the specified level. For details, see “CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL (4-41)“. 14. Next, raise the engine speed and follow the procedure in Step 12 to bleed the air. Repeat this process until no more air comes out.

  • Page 238: Cleaning The Strainer Of The Brake Filter

    MAINTENANCE SERVICE PROCEDURE CLEANING THE STRAINER OF THE BRAKE FILTER WARNING q After the motor is switched off, the parts and oil is very hot and can cause serious burns. Let it cool down before you start working. q Press the brake pedal approx. 15 times to reduce the pressure in the brake accumulators. 1.

  • Page 239: Change Axle Oil

    MAINTENANCE SERVICE PROCEDURE CHANGE AXLE OIL WARNING q When changing the oil, apply the parking brake and secure the front and rear frames with the safety bar. q After the engine is stopped, the parts and oil are at high temperature, and may cause burns. Wait for the temperature to go down before starting the operation.

  • Page 240: Replace Element In Air Conditioner Recirculation Air Filter, Fresh Air Filter

    For details of cleaning the fresh air filter, see “CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER (4- 40)“. CHECK ALTERNATOR, STARTING MOTOR The brush may be worn or have no grease on the bearing, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.

  • Page 241: Clean And Check Turbocharger

    CHECK ACCUMULATOR GAS PRESSURE When carrying out the EVERY 2000 HOURS SERVICE or EVERY YEAR SERVICE or when making periodic replacement of the critical safety parts, please ask your Komatsu distributor to check the accumulator gas pres- sure. CHECK VIBRATION DAMPER Check that there are no cracks or peeling in the outside surface of the rubber.

  • Page 242: Every 4000 Hours Service

    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 abnormality is found, contact your Komatsu distributor for disassembly and repair or replacement. 4-61...
  • Page 243 MAINTENANCE SERVICE PROCEDURE 4-62...
  • Page 244 TECHNICAL DATA...
  • Page 245 Operating weight (including 1 operator: 75 kg) 14.220 (with bolt on cutting edge) Normal load 4.480 Bucket capacity Heaped Engine model Komatsu SAA6D102E diesel engine Flywheel horsepower kW (HP)/rpm 124 (169)/2000 A Overall length 7.475 B Overall height 3.200 C Max. dimension when shaking bucket 5.260...
  • Page 246 TECHNICAL DATA TECHNICAL DATA...
  • Page 247 TECHNICAL DATA NOISE EMISSION LEVELS NOISE EMISSION LEVELS Two signs are attached to the machine that state the noise level produced. In accordance with guideline ISO 6396, the value for the sound pressure level measures is LpA = 72 dB/A. In accordance with EC Directive 2000/14/EC, the guaranteed value for the sound power level measures is LWA = 106 dB/A.
  • Page 248 ATTACHMENTS, OPTIONS...
  • Page 249 General ground conditions 20.5-25-12PR (L3 Rock) Loading products (with bolt-on cutting edge) and crushed rock Hard ground 20.5-25-12PR (L3 Rock) 2.2 m (2.9 cu.yd) BOC indicates a bolt-on type cutting edge. When installing optional tires, please contact your Komatsu distributor.
  • Page 250 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER MACHINE MONITOR WITH LOAD METER EXPLANATION OF COMPONENTS (1) Machine monitor (4) Load meter cancel switch (2) Monitor panel mode selector switch 1 (5) Load meter subtotal switch (3) Monitor panel mode selector switch 2 MACHINE MONITOR For details of the method of handling machine monitor (1), see Section “MACHINE MONITOR (6-6)“.
  • Page 251 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER MONITOR PANEL MODE SELECTOR SWITCH 1 This switch (2) is used to switch the function of the character display. When the switch is released, it automatically returns to its origi- nal position. The basic operation is as follows. Position ( ): Press here to select (confirm) each mode or operation Position ( ):...
  • Page 252 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER LOAD METER SUB TOTAL SWITCH Press switch (5) at the side of the bucket control lever to set the TOTAL LOADED display (when in addition mode) or REMAIN- ING TARGET display (when in remain mode) to 0.
  • Page 253 Lamps (2) go out after the engine starts. If any lamps do not light up there is probably a failure or a disconnection, so please ask your Komatsu distributor to carry out inspection. When the starting switch is turned ON, if the directional lever is not at the neutral position, the central warning lamp lights up and the alarm buzzer sounds intermittently.
  • Page 254 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER TYPES OF WARNING If an abnormality occurs on the machine, or if any switch or lever is operated accidently, the monitor display and buzzer give a warning to inform the operator. Following are the types of warning depending on the level of danger.
  • Page 255 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER CHARACTER DISPLAY PORTION (1) Service meter (4) Failure code display (2) Clock (5) Filter, oil replacement time display (3) Action code display Normally, the service meter is displayed on the character display. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed to recommend suitable action.
  • Page 256 If action code E03 is displayed, stop the machine immediately and check the failure code. For details, see “FAILURE CODE DISPLAY (6-11)“. Inform your Komatsu distributor of the failure code and ask for repairs. If there is a failure on the machine, or it is necessary to change the method of operation, or if inspection or mainte- nance must be carried out, action code E00, E01, E02, or E03 is displayed on the character display in display por- tion (3).
  • Page 257 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER E03: When this code is displayed, stop the machine immedi- ately, check the failure code, and contact your Komatsu distrib- utor for repairs. REMARK The top line of the character display displays “E03“ and the bot- tom line displays “CHECK RIGHT NOW“...
  • Page 258 If an action code is displayed on the character display, check the failure code according to the failure code display method given below. When contacting your Komatsu distributor to request repairs, please inform your distributor of the failure code. Method of displaying failure code 1.
  • Page 259 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER FILTER, OIL REPLACEMENT TIME DISPLAY After completion of the system check and when the starting switch is in the ON position, if any filter or oil item is approach- ing the replacement time, this display (5) shows the item for approx.
  • Page 260 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER REMARK See the section below for details of the procedure for replacing the filter and oil. Engine oil “CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (4-48)“ Engine oil filter “CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (4-48)“...
  • Page 261 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER EMERGENCY STOP ITEM CAUTION If these lamps light up and the buzzer sounds, stop operations immediately and carry out inspection and maintenance of the applicable location. If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the lamp for the location of the abnormality and the central warning lamp will light up.
  • Page 262 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER BRAKE OIL PRESSURE CAUTION LAMP This lamp (1) lights up when the brake oil pressure goes below the specified value. During checks before starting (starting switch at the ON posi- tion, engine stopped) the lamps are lighted up, and when the engine is started, the lamps go out.
  • Page 263 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER BATTERY CHARGE CIRCUIT CAUTION LAMP This lamp (3) lights up when the engine is running to warn the operator that an abnormality has occurrred in the charging cir- cuit. During checks before starting (starting switch at the ON posi- tion, engine stopped) the lamps are lighted up, and when the engine is started, the lamps go out.
  • Page 264 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER CAUTION ITEMS CAUTION If these lamps light up, stop operations quickly and carry out the following action. (1) Axle oil temperature caution lamp (4) Engine cooling water temperature caution lamp (2) Parking brake reminder caution lamp (5) Fuel level caution lamp (3) HST oil temperature caution lamp AXLE OIL TEMPERATURE CAUTION LAMP...
  • Page 265 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 3. Do not keep the brake pedal depressed continuously; use the brake only intermittently. If use of the brake is reduced for a short time in the way recommended above, the axle oil temperature will go down and the caution lamp will go out.
  • Page 266 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER FUEL LEVEL CAUTION LAMP This lamp (5) lights up if the amount of fuel remaining in the fuel tank goes below 31 liters (8.19 US gal). If it lights up, check and add fuel as soon as possible. REMARK Even if the caution lamp lights up, action code “E02“...
  • Page 267 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER INSPECTION AND MAINTENANCE ITEM CAUTION If these lamps light up, stop operations quickly and carry out the following action. (1) Radiator coolant level caution lamp (4) HST oil filter clogging caution lamp (2) Engine oil level caution lamp (5) Air cleaner clogging caution lamp (3) Maintenance caution lamp RADIATOR COOLANT LEVEL CAUTION LAMP...
  • Page 268 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 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. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor lights up if the oil level in the engine oil pan is low.
  • Page 269 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER HST OIL FILTER CLOGGING CAUTION LAMP When the engine is running, this lamp (4) lights up if the HST oil filter is clogged. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up.
  • Page 270 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 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 (5) Pilot lamp for speed range selector switch position (2) Preheating pilot lamp (6) Turn signal pilot lamp (3) Emergency steering pilot lamp...
  • Page 271 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER EMERGENCY STEERING PILOT LAMP (Green) If this lamp (3) lights up when the engine is running or when the machine is operating, it indicates that the condition is normal. If it does not light up, an abnormality has occurred in the emer- gency steering circuit.
  • Page 272 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER HEAD LAMP HIGH BEAM PILOT LAMP This lamp (7) lights up when the head lamp is at high beam. 6-25...
  • Page 273 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER METER DISPLAY PORTION (1) HST oil temperature gauge (3) Fuel gauge (2) Engine coolant temperature gauge (4) Load meter HST OIL TEMPERATURE GAUGE This meter (1) indicates the HST oil temperature. During normal operations, the indicator should be in the white range (A).
  • Page 274 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER FUEL GAUGE This meter (3) indicates the amount of fuel remaining in the fuel tank. If the indicator is at the F position, it indicates that the tank is full. If the indicator is at the E position, it indicates that there is little fuel remaining.
  • Page 275 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER LOAD METER LOAD METER FUNCTIONS (1) Addition mode display (4) Bucket load display (2) Remain mode display (5) Material type display (3) TOTAL LOADED display (addition mode) or (6) Speed display or engine speed display REMAINING TARGET display (remain mode) NOTICE When using the load meter to measure, make sure that the...
  • Page 276 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER LOAD METER ADDITION MODE q For details of the method of switching to the addition mode, see “SETTING ADDITION MODE (6-31)“. q “TOTAL LOADED“ lights up on load meter display (1). q The bucket load is displayed on load meter display (2), and the total load is displayed on display (3).
  • Page 277 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER SELECTION OF DISPLAY FOR TYPE OF LOAD q For details of the method of selecting the type of load, see “SETTING ADDITION MODE (6-31)“ and “SETTING REMAIN MODE (6-33)“. q It is possible to make categories for a maximum of five types of material for TOTAL LOADED or REMAINING TARGET.
  • Page 278 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER HANDLING LOAD METER DISPLAY SETTING ADDITION MODE When carrying out loading operations in the addition mode, refer to “ADDITION FUNCTION (6-41)“ after setting the addition mode. 1. Check that the normal service meter and time are dis- played on the character display.
  • Page 279 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 4. If the display is “REMAINS MODE“, press the (>) or (<) of monitor panel mode selector switch 2 to display “ADDI- TION MODE“. 5. Press the ( ) of monitor panel selector switch 1 and dis- play “MATERIAL <...
  • Page 280 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER SETTING REMAIN MODE When carrying out operations in the remain mode, set to the remain mode. For details of the remain mode func- tions, see “SUBTRACTION FUNCTION (6-43)“. 1. Check that the normal service meter and time are dis- played on the character display.
  • Page 281 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 4. If the display is “ADDITION MODE“, press the (>) or (<) of monitor panel mode selector switch 2 to display “REMAIN MODE“. 5. Press the ( ) of monitor panel selector switch 1 and dis- play “MATERIAL <...
  • Page 282 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 12. The “0“ at the 10 ton position must be changed to “3“, so press the (>) or (<) of monitor panel mode selector switch 2 to change to “3“, then press the ( ) of monitor panel selec- tor switch 1.
  • Page 283 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER TOTAL LOAD DATA DISPLAY 1. Check that the normal service meter and time are dis- played on the character display. 2. Press the ( ) of monitor panel selector switch 1 and dis- play “LOAD METER“.
  • Page 284 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER The total load data for each of A to E and for all data is dis- played on the load meter display. Check the material selection display on load meter display (1). In the example on the right, all of A to E for all data selected light up.
  • Page 285 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER STOPPING CALCULATION 1. Check that the normal service meter and time are dis- played on the character display. 2. Press the ( ) of monitor panel selector switch 1 and dis- play “LOAD METER“. 3.
  • Page 286 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 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.
  • Page 287 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 4. Press the ( ) of monitor panel selector switch 1. “EMPTY BUCKET“ is displayed on the bottom line. 5. Press the ( ) of monitor panel selector switch 1. The dis- play changes to “STEP 1“ on the top line, and “FULLY ROLL BACK“...
  • Page 288 In this case there is need to carry out calibration with load. Please contact KOMATSU distributor to carry out the calibration. ADDITION FUNCTION After setting the addition mode, if the material being handled is “A“...
  • Page 289 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 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.
  • Page 290 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 7. The screen will return to the initial display. REMARK It may not be possible to measure the weight of the load when carrying out the following operations. When the boom is not kept raised continuously for at least 1.5 sec. When the boom is operated to RAISE continuously but the lifting speed is not constant When the boom angle when starting the RAISE operation is near horizontal If the result of the measurement is not displayed on the load meter, start the scooping operation with the bucket at...
  • Page 291 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER REMARK In the condition in Step 1 or Step 2, if the lift arm is lowered to near the travel posture, then raised again to measure the bucket load again, the load meter will think that work was car- ried out for the second loading operation.
  • Page 292 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 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.
  • Page 293 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 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).
  • Page 294 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 4. Press the ( ) of monitor panel mode selector switch 1. The top line displays “ADJUST 23: 59“. The bottom line displays “2000/01/01“. REMARK Once the time is input, the clock will show the correct time from that time on.
  • Page 295 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER PRINTER OUTPUT PRINTOUT MODE (This functions only when the optional printer is installed.) Three types of output mode (A, B, C) can be selected for the load meter printout. For details, see “METHOD OF SELECTING PRINTOUT MODE (6-49)“. A mode: Printout of totals The number of loads and total amount loaded for each type of material are printed out.
  • Page 296 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER METHOD OF SELECTING PRINTOUT MODE (This functions only when the optional printer is installed.) 1. Check that the normal service meter and time are dis- played on the character display. 2. Press the ( ) of monitor panel selector switch 1 and dis- play “LOAD METER“.
  • Page 297 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 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.
  • Page 298 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER OTHER FUNCTIONS OF MACHINE MONITOR The machine monitor also has the following functions. Odometer, filter/oil replacement time reset, telephone number input, language selection, HST selector function, monitor lighting adjustment METHOD OF DISPLAYING ODOMETER Use this when checking the total distance that the machine has traveled.
  • Page 299 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 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.
  • Page 300 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 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. 1. Press the ( ) of monitor panel selector switch 1 and dis- play “LOAD METER“.
  • Page 301 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 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. 1. Press the ( ) of monitor panel selector switch 1 and dis- play “LOAD METER“.
  • Page 302 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER METHOD OF SELECTING HST CHANGING FUNCTION When the speed range selector switch is in 3rd or 4th position, there are two selections available for the HST. Use this when changing the selection. Speed range selector switch position Function 3rd position 4th position...
  • Page 303 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER METHOD OF ADJUSTING MONITOR BRIGHTNESS Do as follows to adjust the brightness of the monitor. 1. Press the ( ) of monitor panel selector switch 1 and dis- play “LOAD METER“. 2. Press (>) or (<) of monitor panel mode selector switch 2 and display “BRIGHTNESS ADJUST“.
  • Page 304 ATTACHMENTS, OPTIONS MACHINE MONITOR WITH LOAD METER 4. Press the ( ) of monitor panel mode selector switch 1. The screen will change to the display shown on the right and it will be possible to adjust the brightness. 5. Press the (>) or (<) of monitor panel mode selector switch 2 to select a level between L and H (available range: 7 stages).
  • Page 305 ATTACHMENTS, OPTIONS HANDLING MULTI-FUNCTION LEVER HANDLING MULTI-FUNCTION LEVER EXPLANATION OF COMPONENTS (1) Work equipment lever (3) Directional selector switch actuation switch (2) Directional selector switch (4) Directional selector pilot lamp WORK EQUIPMENT LEVER Use this lever (1) to operate the lift arm and bucket. NOTICE Do not use the FLOAT position when lowering the bucket.
  • Page 306 ATTACHMENTS, OPTIONS HANDLING MULTI-FUNCTION LEVER Position (e): TILT Tilt When the work equipment 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 Dump lever is returned to the HOLD position.
  • Page 307 ATTACHMENTS, OPTIONS HANDLING MULTI-FUNCTION LEVER DIRECTIONAL SELECTOR PILOT LAMP This lamp (4) displays the position of the directional selector switch under the following conditions. q Directional selector switch operation switch: ON position q Directional lever: N position F lights up: FORWARD N lights up: NEUTRAL R lights up: REVERSE REMARK...
  • Page 308 ATTACHMENTS, OPTIONS HANDLING MULTI-FUNCTION LEVER OPERATION USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE WARNING q When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so be particularly careful when changing direction to travel in reverse.
  • Page 309 ATTACHMENTS, OPTIONS HANDLING MULTI-FUNCTION LEVER 3. Place the directional selector switch actuation switch (3) at the ON position (a). 4. Place the directional selector switch (2) at the F (forward) or R (reverse) position. REMARK When the directional selector switch actuation switch (3) is at the ON position, if the directional lever (1) is oper- ated to FORWARD or REVERSE, the machine will travel in forward or reverse according to the operation of the directional lever, regardless of the position of the directional selector switch (2).
  • Page 310 OK. If the mixer blades are not turning, no automatic lubrication is taking place. To eliminate the malfunction, contact your Komatsu dealer. DISPLAY AND CONTROL UNIT The display and control unit is protected by a transparent plastic cover against splashing water and mechanical damage.
  • Page 311 ATTACHMENTS, OPTIONS CENTRAL LUBRICATION SYSTEM LED-DISPLAY 1. Seven-segment display: Values and operating state 2. Pause time (PAUSE h/lmp) 3. Pump operation (CONTACT min/lmp) 4. Monitoring of system function by means of an external PAUSE h/lmp cycle switch (CS) CONTACT min/lmp 5.
  • Page 312 ATTACHMENTS, OPTIONS CENTRAL LUBRICATION SYSTEM CHANGING THE LUBRICATION INTERVAL TIMES The settings when shipping from factory are as follows: Greasing interval: after 1 hour Greasing time: 10 minutes. Step Display 000 in display flashes Press for more than 2s Automatically indicates first parameter Example: ªPause in timer operation Press briefly LED ªPause flashes...
  • Page 313 ATTACHMENTS, OPTIONS CENTRAL LUBRICATION SYSTEM 6-66...
  • Page 314 INDEX...
  • Page 315 INDEX...
  • Page 316 INDEX INDEX FUSE ................. 3-46 ADJUSTING WORK EQUIPMENT POSTURE .. 3-94 AFTER STARTING ENGINE GENERAL PRECAUTIONS ........2-7 CHECKS ............3-74 GENERAL VIEW ............3-2 OPERATIONS ..........3-74 CONTROLS AND GAUGES ......3-3 AIR CONDITIONER ..........3-49 MACHINE ............3-2 AXLE SERIAL NO.
  • Page 317 INDEX POSITION OF SERVICE MATER TRANSPORTATION PROCEDURE ......1-9 ....3-101 POWER OUTLET TROUBLESHOOTING ........... 3-48 ......... 3-111 PRECAUTIONS FOR MAINTENANCE IF BATTERY IS DISCHARGED ....2-29 ....3-113 PRECAUTIONS FOR OPERATION OTHER TROUBLE ..2-17 3-92 ........3-117 BATTERY TOWING THE MACHINE ............
  • Page 318 NOTES...
  • Page 319 NOTES NOTES NOTES...
  • Page 320 NOTES NOTES...
  • Page 321 © 2003 Komatsu Hanomag GmbH All Rights Reserved Printed in Europe 10.2003...

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