Page 1 The operator and maintenance personnel must read this manual before commencing operation or maintenance. Keep this manual within reach at all times and ensure that operating personnel read it at regular intervals. © 2017 KOMATSU All Rights Reserved Printed in Europe 08-2017...
Page 3 Komatsu or Ko- matsu approved rebuilt parts or assemblies or others parts of equivalent quality, and that the engine be serviced by an authorized Komatsu distribu- tor. Failure to follow these recommendations could result in ineffective serv- ice, damage to the product or safety risks (including personal injury or death).
Page 4: Eu Directives
(1) on the left side of the operator's seat. If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement.
Page 5 The transmitter unit must be spatially separated from the vehicle’s electronic system. • Make sure when installing the antenna that this is installed correctly with good earth connection between antenna and vehicle mass. Also observe Komatsu and manufacturer’s installation instructions for wiring, installation and maximum permit- ted power consumption.
Page 6: Safety Information
SAFETY INFORMATION FOREWORD SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 7: Safety Labels
Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for ques- tions regarding information in this manual.
Page 8: Noise Emission Levels
NOISE EMISSION LEVELS FOREWORD NOISE EMISSION LEVELS A sign is attached to the machine that state the noise level produced. • Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A weighted emission sound pressure level at the operator's position is 2.5 dB, in accordance with ISO 11201.
Page 9: Vibration Level
FOREWORD VIBRATION LEVEL VIBRATION LEVEL When used for its intended purpose, levels of vibration for the earth working machine transmitted from the oper- ator’s seat are lower or equal to the test vibrations for the relative machinery class in compliance with ISO 7096. The actual acceleration value of the upper limbs is less than 2.5 m/s .
Page 10: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Digging work • Leveling work • Dozing work • Loading work For details of the work procedure, see “RECOMMENDED APPLICATIONS”.
Page 11: Engine Technology To Conform Exhaust Gas Emission
Diesel Exhaust Fluid is the aqueous urea solution for the SCR system. The Komatsu Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the ex- haust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decom- poses the nitrogen oxides into nitrogen and water.
Page 12: Product Information
PRODUCT INFORMATION FOREWORD PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE This is located at the center of the front frame on the right side of the machine.
Page 13: Rops/Fops Serial Plate Location
ROPS/FOPS SERIAL PLATE LOCATION AXLE SERIAL PLATE LOCATION This plate is located on the right of front axle and on the left of rear axle. PRODUCED BY KOMATSU GERMANY GmbH, HANNOVER FEDERAL REPUBLIC OF GERMANY FOR Komatsu Ltd.,Tokyo,Japan MODEL PART NO.
Page 14: Seat Plate Location
SERVICE METER LOCATION It is at the center bottom of the machine monitor. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturer name Komatsu Germany GmbH Address Hanomag Strasse 9 30449 Hannover Germany 1-12...
Page 15 FOREWORD PRODUCT INFORMATION Distributor name Address Phone/Fax Service personnel 1-13...
Page 16: Declaration Of Conformity
DECLARATION OF CONFORMITY FOREWORD DECLARATION OF CONFORMITY The manufacturer: Komatsu Germany GmbH Hanomag Straße 9 30449 Hannover Germany Declares that this machine: WA200-8* Fulfils all the relevant provisions of following EC Directives: Machine Directive 2006/42/EC Electro Magnetic Compatibility Directive 2004/108/EC until 19 April 2016...
Page 17: Retrofitting By Third-Party Suppliers
In the event of tools (e.g. loading shovels) being retrofitted by a third-party supplier, the technical specifications of the manufacturer must be taken into account. For this purpose, or for further information, please be sure to consult Komatsu or your local Komatsu dealer. 1-15...
Page 18: Explanation Of Acronyms
EXPLANATION OF ACRONYMS FOREWORD EXPLANATION OF ACRONYMS Acronyms Stand for: KDPF Komatsu Diesel Particulate Filter KVGT Komatsu Variable Geometry Turbo KCCV Komatsu Closed Crankcase Ventilation Selective Catalytic Reduction Diesel Exhaust Fluid ECSS Electrically Controlled Suspension System 1-16...
Page 19: Table Of Contents
FOREWORD TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 EU DIRECTIVES ..........................1-2 SAFETY INFORMATION .......................... 1-4 SAFETY LABELS ............................. 1-5 NOISE EMISSION LEVELS ........................1-6 VIBRATION LEVEL........................... 1-7 INTRODUCTION ............................1-8 MAIN USE OF MACHINE ........................1-8 DIRECTIONS OF MACHINE......................
Page 20 OTHER TROUBLE......................... 3-222 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................
Page 21 CONSUMABLE PARTS LIST ......................7-3 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-4 LUBRICATION CHART ........................7-4 METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-7 1-19...
Page 22 TABLE OF CONTENTS FOREWORD INDEX................................8-1 1-20...
Page 23: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
Page 24: Safety Labels
If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...
Page 25 SAFETY SAFETY LABELS (1) Caution before operating (16) Caution for modification of ROPS/FOPS (2) Caution when leaving operator's seat (17) Prohibition of start by short-circuiting (3) Caution when traveling in reverse (18) Caution for cleaning cooler core (4) Caution for electric cables (19) Emergency escape (5) Prohibition of trespassing (20) Caution when closing emergency escape right...
Page 26: Contents Of Safety Labels
SAFETY LABELS SAFETY CONTENTS OF SAFETY LABELS Caution before operating “09651-A0481” • Warning! • Read manual before operation, maintenance, disassembly, assembly and transportation. Caution when leaving operator's seat “09654-C0481” • Sign indicates a hazard of unexpected moving of stopped machine. •...
Page 27 SAFETY SAFETY LABELS Caution for electric cables “09801-C0481” • Sign indicates an electrocution hazard if machine is brought too near electric power lines. • Keep a safe distance from electric power lines. Prohibition of trespassing “09162-C0641” • Sign indicates a crush hazard between the articulating parts of vehicle.
Page 28 SAFETY LABELS SAFETY Caution for high-temperature coolant “09653-A0641” • Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot. • Allow radiator or hydraulic tank to cool before removing cap. Caution for high-temperature oil and hydraulic oil “09653-A0641”...
Page 29 SAFETY SAFETY LABELS Caution for explosion “09659-A0641” • Sign indicates an explosion hazard. • Never drill, cut with gas, hit or disassemble. Also keep open flame away. Caution for explosion “09659-A0881” • Sign indicates an explosion hazard. • Never drill, cut with gas, hit or disassemble. Also keep open flame away.
Page 30 SAFETY LABELS SAFETY Caution while engine is running “09667-A0880” • Sign indicates a hazard of rotating parts, such as belt. • Turn off before inspection and maintenance. Caution for nearing machine “09806-C1201” • Sign indicates a hazard of being run over by moving vehi- cle.
Page 31 Any modification is prohibited. • ROPS or FOPS may provide less protection if it has been structurally damaged or involved roll-over. Con- sult Komatsu Distributor in that case. • Always wear seat belt when moving. Prohibition of start by short-circuiting “09842-A0642”...
Page 32 SAFETY LABELS SAFETY Emergency escape “425-93-51110” Caution when closing emergency escape right window “421-926-4990” Caution for hot exhaust pipe “09817-A0753” • Sign indicates a burn hazard from touching heated parts, such as engine, motor, or muffler during or right after oper- ation.
Page 33 SAFETY SAFETY LABELS Caution for high-pressure common rail “6754-71-1811” • Do not open high pressure fuel system with engine run- ning. Engine operation causes high fuel pressure. • High pressure fuel spray can cause serious injury or death. 5 3 65 9 4 2 Caution for blast site (Machines equipped with KOMTRAX) “09845-00480”...
Page 34 SAFETY LABELS SAFETY Caution for handling DEF “09632-61480” • DEF Only. To avoid engine damage or fire, fill with DEF only. • Never use diesel fuel. Caution for high-temperature coolant “23B-53-71190” • Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot.
Page 35: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 36 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical compo- nents.
Page 37: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE PRECAUTIONS TO PREVENT FIRE ACTIONS IF FIRE OCCURS • Turn the starting switch to OFF position, and stop the engine. • Use the handrails and steps to escape from the machine. •...
Page 38: Precautions When Getting On Or Off Machine
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring. Fire caused from piping Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts.
Page 39 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • Do not try to get on a tire from the step in the rear side of the machine or the step beside the cab. • Do not get on or off the machine with tools in your hand. NO JUMPING ON OR OFF MACHINE Getting on or off the moving machine can cause serious personal injury or death.
Page 40: Do Not Get Caught
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY Whenever leaving the machine, be sure to lower the work equipment to the ground, lock the work equipment by pressing work equipment lock switch (1) (pilot lamp lights up) and stop the engine by setting parking brake switch (2) to ON (opera- tion) position (A).
Page 41: Unauthorized Modification
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
Page 42: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 43 SAFETY PRECAUTIONS FOR OPERATION Voltage of Cables Safety Distance 154000 V Min. 5 m 187000 V Min. 6 m 275000 V Min. 7 m 500000 V Min. 11 m • To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera- tor's seat, and be careful not to touch the chassis with any exposed part of your body.
Page 44: Start Engine
Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. START ENGINE USE WARNING TAGS If there is a “DANGER! Do NOT operate!”...
Page 45 SAFETY PRECAUTIONS FOR OPERATION • Check the coolant level, fuel level, DEF level, and oil level in engine oil pan, check for clogging of the air cleaner, and check for damage to the electric wiring. • Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake pedal, and check that the pedals work properly.
Page 46: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cables. • When connecting a normal machine to a failed machine with the jumper cables, always use the normal machine with the same battery voltage as the failed machine.
Page 47 SAFETY PRECAUTIONS FOR OPERATION • Prohibit other personnel to get on the machine. • If there are any persons in the area around the machine, there is danger that they may be hit or caught by the ma- chine, and this may lead to serious personal injury or death.
Page 48 PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always observe the following. • Keep the work equipment at height (A) of approximately 20 to 30 cm above the ground. In case of emergency, lower the work equipment to the ground immediately to help stopping the machine.
Page 49 SAFETY PRECAUTIONS FOR OPERATION • If the engine cannot be started again after it has stopped, turn the starting switch key to ON position, and immediately operate the multifunction mono-lever to lower the work equipment to the ground. (The accumu- lator is capable of working only for a limited time after the engine is stopped.) •...
Page 50 PRECAUTIONS FOR OPERATION SAFETY • Do not dig the work face under an overhangs. There is a danger that the work face will collapse. • When digging, never thrust the bucket into a load at an an- gle. This will bring an excessive load on the machine and will reduce the machine life.
Page 51: Precautions For Transportation
• This machine needs to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. • Lock the frame with the frame lock bar to prevent the machine from articulating.
Page 52: Towing And Being Towed
PRECAUTIONS FOR OPERATION SAFETY • Always use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough to provide a safe loading slope. Take suitable steps to prevent the ramps from moving out of position or coming off. (1) Chocks (2) Ramp (3) Width of ramps: Same width as tires...
Page 53: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the “DAN- GER! Do NOT operate!” warning tag. If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 54 END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death.
Page 55 SAFETY PRECAUTIONS FOR MAINTENANCE • Set frame lock bar (4) to LOCK position (L) to lock the front and rear frame. TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent accident, do not perform maintenance with the engine running. When it is necessary to perform the maintenance with the engine running, always observe the following.
Page 56 PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS • Appoint a leader before starting removal or installation operations for attachments. • Place attachments that have been removed from the ma- chine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area.
Page 57: Precautions For Check And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE USE PROPER TOOLS Use the tools suited to the task and use them correctly. Using damaged, deformed, or low quality tools, or making improper use of the tools may cause serious personal injury or death. PRECAUTIONS FOR CHECK AND MAINTENANCE TURN BATTERY DISCONNECT SWITCH TO OFF POSITION In the following cases, turn the starting switch to OFF position and check that the system operating lamp is off.
Page 58 PRECAUTIONS FOR MAINTENANCE SAFETY Danger from dilute sulphuric acid When the battery is being charged, flammable hydrogen gas is generated and may explode. In addition, the battery electrolyte includes dilute sulphuric acid. Any mistake in handling may cause serious personal injury, explosion, or fire. Always ob- serve the following.
Page 59 If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 60 • When disposing of the accumulator, the gas must be re- leased. Ask your Komatsu distributor to perform this work. PRECAUTIONS FOR COMPRESSED AIR • When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by flying dust or particles.
Page 61: Tires
To ensure safety, always observe the following. • Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special tech- nology, so always ask your Komatsu distributor to perform these operations. • Use only specified tires and inflate them to the specified pressure.
Page 62 PRECAUTIONS FOR MAINTENANCE SAFETY • If the rim parts are not fitted properly when the tire is being pumped up, there is a danger that the rim parts may fly off, so set up a protective fence around the tire, and do not stand directly in front of the rim. Stand beside the tread when pumping up the tire.
Page 63: Precautions For Def
SAFETY PRECAUTIONS FOR DEF PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...
Page 65: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 66: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Bucket (10) Rear full-length fender (2) Front wheel (11) Rear wheel (3) Bell crank (12) Stepladder (4) Bucket cylinder (13) Chock (5) Turn signal lamp (14) Lift cylinder (6) Headlamp (15) Boom (7) Rearview mirror (16) Rear working lamp (8) Front working lamp...
Page 67: Controls And Gauges Names
OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES (1) Front switch panel (9) Turn signal lever (2) Directional lever (9) Dimmer switch (3) Engine shutdown secondary switch (10) Parking brake switch (4) Hazard lamp switch (11) Monitor switch (5) Speed range selector switch (12) Cigarette lighter (6) Machine monitor (13) Rearview monitor brightness adjustment switch...
Page 68 GENERAL VIEW OPERATION (17) Directional selector switch (24) Rear wiper switch (18) Multifunction mono-lever (25) Steering tilt lock lever (19) PCS (Proportional Control Switch) (if equipped) (26) L.H. brake pedal (20) Accelerator pedal (27) Max. traction switch (21) R.H. brake pedal (28) Room lamp switch (22) Starting switch (29) Rear heated wire glass switch...
Page 69 OPERATION GENERAL VIEW MACHINE MONITOR EQUIPMENT NAME General view (A) LCD unit (C) Meter unit (B) LED unit (1) HST oil temperature gauge (15) Engine tachometer (2) HST oil temperature caution lamp (16) Speedometer (3) Engine coolant temperature caution lamp (17) Fuel level caution lamp (4) Engine coolant temperature gauge (18) Fuel gauge...
Page 70 GENERAL VIEW OPERATION Display of liquid crystal unit (A) Standard screen (D) Warning screen (B) ECO guidance screen (E) User menu screen (C) Maintenance time warning screen (27) Message display (37) Fan reverse rotation display (28) Directional selector pilot lamp (38) Secondary steering pilot lamp (if equipped) (29) ECSS pilot lamp (if equipped) (39) Aftertreatment devices regeneration display...
Page 71: Other Equipment Name
OPERATION GENERAL VIEW OTHER EQUIPMENT NAME Inside of cab (1) 24 V power supply (8) Cab door handle (2) Rearview monitor (9) Fuse (3) Ashtray (10) AUX (4) Open knob for alternate exit of cab (11) Fire extinguisher (if equipped) (5) Cool box (12) Unlock knob for slide window of cab (6) Cup holder (13) Open handle for cab L.H.
Page 72 GENERAL VIEW OPERATION Outside of cab (1) Frame lock bar (4) DEF tank (2) DEF pump (5) Slow-blow fuse (3) DEF filter...
Page 73 OPERATION GENERAL VIEW (6) Towing pin (11 Dust indicator (7) Backup alarm (12) Komatsu Closed Crankcase Ventilation (hereafter KCCV) ventilator (8) Grease pump holder (13) System operating lamp (9) SCR assembly (14) Battery disconnect switch (10) DEF injector...
Page 74: Explanation Of Components
EXPLANATION OF COMPONENTS OPERATION EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT FF: Failure display screen (A) Warning display...
Page 75 NOTICE If the lamps, alarm buzzer, etc. do not work, the machine monitor may be failed or the electric wiring may have breakage. In this case, ask your Komatsu distributor for repair. REMARK When the engine is started, the battery voltage may suddenly drop depending on the temperature and the bat- tery condition.
Page 76 5 seconds, and then screen goes out. End screen with message If there is any message from your Komatsu distributor, it is displayed on end screen DD for 5 seconds, and then the screen goes out. In this case, turn the starting switch to ON position to re-check the message, and if it is the message requesting response, send back your reply.
Page 77 Starting screen BB without inputting ID number. REMARK • Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identification function. • Depending on the set value of ID holding time, even if inputting ID number for operator identification func- tion is set, the ID number input screen LL (with SKIP) or MM (without SKIP) may not be displayed while the starting switch is turned to ON position.
Page 78 Be careful not to use it for the purpose of security enhance- ment. Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third person.
Page 79 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE If any trouble occurs during operation, the standard screen BB changes to the failure display screen FF. When ENTER switch is pressed while guidance icon (1) is dis- played, the “Current Abnormality”...
Page 80 EXPLANATION OF COMPONENTS OPERATION (1) HST oil temperature caution lamp (7) Seat belt caution lamp (2) Engine coolant temperature caution lamp (8) Action level (3) Warning display (9) Brake oil pressure caution lamp (4) Warning display (10) Fuel level caution lamp (5) Centralized warning lamp (11) DEF level caution lamp (6) Guidance icon...
Page 81 │ ing. ↓ If the condition is not improved, check the fail- ure code and ask your Komatsu distributor for inspection and maintenance. Some functions may be restricted from use, but the machine can operate. When you finish the Does not...
Page 82 (A) Caution lamp (B) Action level (C) Failure code Code to indicate the content of the failure. Notify it when calling your Komatsu distributor. (D) Failure name (E) Message Take appropriate remedies according to the displayed message. (F) Contact telephone number The telephone number of the contact such as your Komatsu distributor is displayed.
Page 83 OPERATION EXPLANATION OF COMPONENTS (G) Guidance icon On the “Current Abnormality” list screen, the following switches displayed in guidance icon (G) can be operated. UP switch: Moves to the previous page. When on the first page, it moves to the last page. DOWN switch: Moves to the next page.
Page 84 At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance. Action level is not displayed and lamp lights up in red If the brake oil pressure is below the specified value while the engine is stopped, the caution lamp lights up in red.
Page 85 The caution lamp lights up in yellow. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for the inspection and maintenance as needed. WORK EQUIPMENT SYSTEM CAUTION LAMP The work equipment system caution lamp warns about abnor- mality in the work equipment system.
Page 86 EXPLANATION OF COMPONENTS OPERATION DEF LEVEL CAUTION LAMP DEF level caution lamp alerts when DEF tank level becomes low. Whenever the caution lamp lights up in red, immediately add DEF. Fault conditions that result in activation of the Inducement strat- egy for engine derates to prompt to maintain or repair the emis- sion control system.
Page 87 The caution lamp lights up in yellow. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for the inspection and maintenance as needed. HST OIL FILTER CLOGGING CAUTION LAMP HST oil filter clogging caution lamp warns about clogging of the HST oil filter.
Page 88 The caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
Page 89 The caution lamp lights up in red. At the same time, the central- ized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance.
Page 90 At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, stop the engine, then ask your Komatsu distributor for inspection and maintenance. ENGINE OVERRUN CAUTION LAMP The engine overrun caution lamp warns the operator that the engine speed is higher than the allowable range.
Page 91 The caution lamp lights up in yellow. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for the inspection and maintenance as needed. AIR CONDITIONER SYSTEM CAUTION LAMP Air conditioner system caution lamp warns about abnormality in air conditioner system.
Page 92 • By default, the maintenance time caution lamp (yellow) is set to light up when the remaining time reaches 30 hours. However, you can change this setting. To change the setting, ask your Komatsu distributor. CENTRALIZED WARNING LAMP The centralized warning lamp lights up in red and at the same time the alarm buzzer sounds intermittently when the machine is under the following condition.
Page 93 OPERATION EXPLANATION OF COMPONENTS Machine conditions under which centralized warn- Other monitor displays ing lamp lights up When the directional change operation is per- formed during the high speed travel at the speed range of 3rd or 4th. When the directional lever is not in NEUTRAL po- The directional switch caution lamp lights up sition (N) while the directional selector switch is ef- in red.
Page 94 EXPLANATION OF COMPONENTS OPERATION (9) Headlamp (high beam) pilot lamp (16) Preheating pilot lamp (10) 2-stage low idling pilot lamp (17) Fan reverse rotation display (11) Clearance lamp pilot lamp (18) Secondary steering pilot lamp (if equipped) (12) Work equipment lock pilot lamp (19) Aftertreatment devices regeneration display (13) Shift lever position display (20) ECO guidance...
Page 95 OPERATION EXPLANATION OF COMPONENTS HEADLAMP (HIGH BEAM) PILOT LAMP The headlamp (high beam) pilot lamp lights up when the head- lamps are set to high beam. CLEARANCE LAMP PILOT LAMP The clearance lamp pilot lamp lights up when the clearance lamps are turned on.
Page 96 EXPLANATION OF COMPONENTS OPERATION 2-STAGE LOW IDLING PILOT LAMP The 2-stage low idling pilot lamp lights up when the 2-stage low idling is effective. FAN REVERSE ROTATION DISPLAY The fan reverse rotation display lights up when performing the radiator fan reverse rotation manually, or when the cycle time which is set in the automatic reverse rotation mode has come.
Page 97 EXPLANATION OF COMPONENTS MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. (A): There is unread message (B): There is any read message to which no reply is made. To read the message, see “CHECK MESSAGE”.
Page 98 EXPLANATION OF COMPONENTS OPERATION SECONDARY HST TRAVEL SWITCH PILOT LAMP The secondary HST travel switch pilot lamp lights up when the secondary HST travel switch is turned on. At the same time, the alarm buzzer sounds intermittently. STEERING LOW OIL PRESSURE CAUTION LAMP (if equipped) Steering low oil pressure pilot pump lights up in red when the steering pressure is low.
Page 99 OPERATION EXPLANATION OF COMPONENTS WORK EQUIPMENT LOCK PILOT LAMP The work equipment lock pilot lamp lights up when the work equipment is locked. This pops up on the screen when the work equipment is switched from the unlock mode to the lock mode. PARKING BRAKE PILOT LAMP The parking brake pilot lamp lights up when the parking brake is applied.
Page 100 EXPLANATION OF COMPONENTS OPERATION When the time until engine output power limitation starts is 1 to 8 hours “Approx. * hours remaining to DEF refill caution.” is displayed. When the time until engine output power limitation starts is less than 1 hour “DEF refill caution will appear soon.”...
Page 101 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY SPEEDOMETER The speedometer indicates the travel speed of the machine. ENGINE TACHOMETER The engine tachometer indicates the engine speed. If the engine speed is higher than the allowable range during operation, the engine overrun caution lamp lights up in red. At the same time, the centralized warning lamp lights up and alarm buzzer sounds intermittently.
Page 102 EXPLANATION OF COMPONENTS OPERATION If the HST oil temperature becomes less than 10 °C, the caution lamp is lit in white, and the travel speed accel- eration is limited. Perform the warm-up operation to raise the HST oil temperature by referring to “METHOD FOR RUNNING-IN THE NEW MACHINE (3-163)”.
Page 103 OPERATION EXPLANATION OF COMPONENTS REMARK Even if the gauge is in orange range (A), it is not a machine trouble. Target fuel consumption (B) displayed by ECO gauge can be changed as necessary. For the method of changing the target value, see “SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE”.
Page 104 EXPLANATION OF COMPONENTS OPERATION Clock display Indicates the current time. (A): 12-hour display (B): 24-hour display REMARK If the battery is disconnected for a long period for storage etc., the time information may be lost. For the method of setting and correcting the time and changing the display of the clock, see “CLOCK ADJUSTMENT”.
Page 105 OPERATION EXPLANATION OF COMPONENTS REMARK • Immediately after turning the starting switch to ON position and during the engine is running, DEF level cau- tion lamp (1) lights up in white. However, this does not indicate abnormality. • In cold weather, DEF level cannot be detected and DEF level caution lamp (1) lights up in white for approxi- mately 1 hour.
Page 106 EXPLANATION OF COMPONENTS OPERATION REMARK • The switches available on each screen can be checked with the guidance icon. • This function is not available when you press a switch not marked by the guidance icon or you press the guidance icon itself.
Page 107 OPERATION EXPLANATION OF COMPONENTS RETURN SWITCH Pressing RETURN switch cancels a selection or changes, and returns the screen to the previous screen or the standard screen. UP SWITCH Pressing UP switch moves the cursor up by one item. When on the first line, it moves to the last line.
Page 108 EXPLANATION OF COMPONENTS OPERATION USER MENU When menu switch (1) is pressed on the standard screen while the machine is stopped, the user menu screen is displayed to enable you to configure and confirm machine settings. The user menu consists of the following kinds. The menu screen can be changed by pressing the menu switch (1).
Page 109 OPERATION EXPLANATION OF COMPONENTS (C) “Aftertreatment Devices Regeneration” • Setting for “Regeneration Disable” • Operation of “Manual Stationary Regeneration” (D) “SCR Information” • Check of DEF level • Information on DEF system (E) “Maintenance” • Check and reset of various maintenance remaining times (F) “Monitor Setting”...
Page 110 EXPLANATION OF COMPONENTS OPERATION On the user menu screen, it is possible to perform the following operations with the switches. (2) UP switch Moves to the item above. When on the first item, it moves to the last item. (3) DOWN switch Moves to the item below.
Page 111 OPERATION EXPLANATION OF COMPONENTS OPERATING RECORD The “Operation Records” screen displays the following informa- tion on a daily basis or during the split measurement period. • “Working Hours (Engine On)”: The time during which the engine is running • “Average Fuel Consumption”: Average of the fuel con- sumed while the engine is running •...
Page 112 EXPLANATION OF COMPONENTS OPERATION When display of “Average Fuel Consumption Display” is set to “Split Time”, and split time measurement is stopped (C) Display while measurement is stopped (D) Dates and times when the measurement is started and stopped To start the split time measurement, see the guidance icon and press ENTER switch (1).
Page 113 OPERATION EXPLANATION OF COMPONENTS When “Average Fuel Consumption Display” is set to “1 Day” “1 Day” is displayed on the place shown with arrow in the right figure. When “Average Fuel Consumption Display” is set to “Split Time”, and split time is measured (A) Display during measurement (B) Date and time when measurement is started...
Page 114 EXPLANATION OF COMPONENTS OPERATION FUEL CONSUMPTION RECORD The “Average Fuel Consumption Record” screen alternately displays the following graphs. • Average fuel consumption for the “Last 12 hours” • Average fuel consumption for the “Last 7 days”. Select “Average Fuel Consumption Record” from the “Energy Saving Guidance”...
Page 115 OPERATION EXPLANATION OF COMPONENTS To clear a graph, see the guidance icon and press ENTER switch (1). When the confirmation screen is displayed, press ENTER switch (1) again to clear or press RETURN switch (3) to cancel clearing. REMARK If clearing is performed while the graph of the “Last 12 hours” is displayed, only the graph of the “Last 12 hours”...
Page 116 EXPLANATION OF COMPONENTS OPERATION Select “Average Fuel Consumption Display” from “Configu- rations” menu, then press ENTER switch (1). Select “1 Day” or “Split Time”, then press ENTER switch (1). The default is “1 Day”. To cancel, press RETURN switch (2). “1 Day”...
Page 117 OPERATION EXPLANATION OF COMPONENTS Select “ECO Gauge Display” from the “Configurations” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the ECO gauge. “OFF” Does not display the ECO gauge. To cancel, press RETURN switch (2). The default is “ON”.
Page 118 EXPLANATION OF COMPONENTS OPERATION Select “ECO Gauge Display Fuel Target Value” from “Con- figurations” menu, then press ENTER switch (1). Use UP switch (2) or DOWN switch (3) to set the value, and press ENTER switch (1). (2) UP switch Increases the target fuel consumption value by 1 ℓ/h.
Page 119 OPERATION EXPLANATION OF COMPONENTS Select “ECO Guidance Display ” from “Configurations” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the ECO guidance. “OFF” Does not display the ECO guidance. To cancel, press RETURN switch (2). The default is “ON”.
Page 120 EXPLANATION OF COMPONENTS OPERATION Select “ECO Guidance Display at Key OFF” from “Configu- rations” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the operational advice on the end screen. “OFF” Does not display the operational advice on the end screen. To cancel, press RETURN switch (2).
Page 121 OPERATION EXPLANATION OF COMPONENTS RADIATOR FAN MANUAL REVERSE MODE CAUTION When rotating the fan in the reverse direction, beware extremely that dirt will not fly out and cloth, etc. will not be wound in the fan. Dust may be blown up. Check that there is no person around the machine while the fan is rotating in the reverse direction.
Page 122 EXPLANATION OF COMPONENTS OPERATION Fan reverse rotation pilot lamp (3) flashes, then lights up. If the condition for reversing the fan is not satisfied, changeover condition waiting pilot lamp (4) lights up in red. Set the engine speed to high idle and perform thecleaning. After finishing the cleaning, set the engine speed to low idle.
Page 123 The default is “Mode A”. When you want other than above settings for the duration and cycle of the automatic fan reverse rotation, consult your Komatsu distributor. REMARK The fan rotation switches from the normal direction to the reverse direction only when all of the following conditions are met.
Page 124 EXPLANATION OF COMPONENTS OPERATION When the set changeover time elapses, fan reverse rota- tion pilot lamp (2) flashes and lights up. If the condition for reversing the fan is not satisfied, changeover condition waiting pilot lamp (3) lights up in red. The fan returns from the reverse rotation to the normal when the set duration for the reverse rotation elapses.
Page 125 OPERATION EXPLANATION OF COMPONENTS Select “Traction Level Selection” on “Machine Setting and Information” menu, then press ENTER switch (1). Select the traction level in accordance with the operating condition, then press ENTER switch (1). “Level A” The rim pull is large. It is suitable for loading heavy target material and on the ground not slippery.
Page 126 EXPLANATION OF COMPONENTS OPERATION Select “Reverse Travel Speed Range Limit” on “Machine Setting and Information” menu, and press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “OFF” OFF: Reverse speed range is not limited. “ON” Even when the travel speed range is set in 3rd or 4th, the reverse travel speed range is limited to 2nd or below.
Page 127 OPERATION EXPLANATION OF COMPONENTS Press ENTER switch (1) to reset or press RETURN switch (2) to cancel resetting. AUTO IDLE STOP TIMER SETTING It is used to stop the engine automatically when the idle state continued for a predetermined time. The auto idle stop works only when all of the following conditions are met.
Page 128 EXPLANATION OF COMPONENTS OPERATION The operating time can be selected from 5 minutes to 60 minutes. REMARK Selecting “OFF” disables operation of the auto idle stop. If the idle state is continued up to 30 seconds before the current auto idle stop timer setting, the countdown screen is displayed on the standard screen.
Page 129 OPERATION EXPLANATION OF COMPONENTS SCR INFORMATION Each item in “SCR Information” menu (D) is for displaying infor- mation related to SCR and DEF. MAINTENANCE SCREEN SETTING Each item on “Maintenance” menu screen (E) is used for dis- playing and setting the notification relevant to maintenance. On the “Maintenance”...
Page 130 “Coolant Change” are not set initially. If you want to change the setting for the maintenance interval and the maintenance notice time, consult your Komatsu distrib- utor. When the maintenance time caution lamp (2) is lit on the stand- ard screen, press the menu switch, and the screen automati- cally displays the “Maintenance”...
Page 131 Input the password for restriction of use by using the nu- meric keypad, then press ENTER switch (1). REMARK For the setting, changing, or canceling the password, ask your Komatsu distributor. The screen changes to Maintenance Due Time Reset screen. When ENTER switch (1) is pressed, the following reconfir- mation screen is displayed.
Page 132 EXPLANATION OF COMPONENTS OPERATION Select “Rearview Monitor Setting” on the “Monitor Setting” menu screen, and press ENTER switch (1). Reference line display The is used to change ON/OFF of the reference line on the rearview monitor. Select “Guide Line Display Mode” from the “Rearview Monitor Setting”...
Page 133 OPERATION EXPLANATION OF COMPONENTS Select “Reverse-interlock Selection mode” on the “Rear- view Monitor Setting” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays images on the rear view monitor only when trav- eling in reverse.
Page 134 EXPLANATION OF COMPONENTS OPERATION Select “Meter Display Selection” on the “Monitor Setting” menu screen, then press ENTER switch (1). SELECT L.H. METER DISPLAY This is used for the selection of the items to be displayed on the L.H. meter display. Select “LH Meter Display Selection”...
Page 135 OPERATION EXPLANATION OF COMPONENTS SELECT R.H. METER DISPLAY This is used for the selection of the items to be indicated on the R.H. meter display. Select “RH Meter Display Selection” on the “Meter Display Selection” menu, then press ENTER switch (1). Select the items to be displayed, then press ENTER switch (1).
Page 136 EXPLANATION OF COMPONENTS OPERATION Adjust the brightness by using the switch panel. The brightness can be adjusted individually in the day and night modes. (1) Menu switch Brightness is set to default. (2) UP switch Brightness increases. (Moves the indicator to the right by one division.) (3) DOWN switch Brightness decreases.
Page 137 OPERATION EXPLANATION OF COMPONENTS Select “GPS Synchronization” from the “Clock Adjustment” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” Sets the date and time automatically. “OFF” Does not set the date and time automatically. (Can be set manually.) REMARK This setting is held even if the starting switch is turned to OFF...
Page 138 EXPLANATION OF COMPONENTS OPERATION Select “Calendar” from the “Clock Adjustment” menu, then press ENTER switch (4). REMARK As long as “ON” is selected for the “GPS Synchronization”, “Calendar” is not selectable. The “Calendar” screen is displayed. When year display (A) is highlighted in yellow, operate the switches as follows to change year display.
Page 139 OPERATION EXPLANATION OF COMPONENTS When day display (C) is highlighted in yellow, operate the switches as follows to change day display. When it is not necessary to change the day setting, press ENTER switch (4). (1) UP switch Advances calendar one day. (2) DOWN switch Puts calendar back one day.
Page 140 EXPLANATION OF COMPONENTS OPERATION When minute display (E) is highlighted in yellow, operate the switches as follows to change minute display. When it is not necessary to change the minute setting, press ENTER switch (4). (1) UP switch Advances time one minute. (2) DOWN switch Puts time back one minute.
Page 141 OPERATION EXPLANATION OF COMPONENTS Select “Daylight Saving Time” from the “Clock Adjustment” menu, then press ENTER switch (1). Select “ON” or “OFF”, then press ENTER switch (1). “ON” Displays the time 1 hour forward. “OFF” Returns the time to the original. REMARK Daylight saving time or summer time means moving the clock forward an hour to take advantage of the fact that the sun rises...
Page 142 The “Operator ID” menu is not displayed when the operator identification function is disabled. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi- fication function. WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted, the identified ID is displayed in the column of “Operator ID”...
Page 143 OPERATION EXPLANATION OF COMPONENTS When the starting switch is ON and “SKIP” is selected, “****” is displayed in the column of “Operator ID” on the “Monitor Set- ting” menu screen. Select “Operator ID” on the “Monitor Setting” menu screen, then ENTER switch (1) for 1 second. The “Operator ID Change”...
Page 144 EXPLANATION OF COMPONENTS OPERATION • When you press menu switch (2) on the “Operator ID Change” screen, a message is displayed below and the screen returns to the “Monitor Setting” menu screen. On the “Monitor Setting” menu screen, as the same way when the starting switch is ON and “SKIP”...
Page 145 In this case, the identified ID is not changed. MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this User Message menu (G). When there is any message, message display (1) of the stand- ard screen lights up.
Page 146 EXPLANATION OF COMPONENTS OPERATION REMARK • While message display (1) is lit on the standard screen, when menu switch (2) is pressed, User Message menu screen (G) is displayed automatically. • When the starting switch is turned OFF while there is any unread message, the message is displayed on the end screen, and when the monitor is started next time, the message changes to a read message.
Page 147 NOTICE If the monitor screen is displayed during other operations while the starting switch is at OFF position, there is proba- bly a failure in the equipment, so ask your Komatsu dis- tributor for inspection. 3-83...
Page 148: Switches
EXPLANATION OF COMPONENTS OPERATION SWITCHES g0020101 (1) ECSS switch (if equipped) (2) Front working lamp switch 3-84...
Page 149 OPERATION EXPLANATION OF COMPONENTS (3) Engine shutdown secondary switch (17) Room lamp switch (4) Speed range selector switch (18) Rear heated wire glass switch (5) Hazard lamp switch (19) Secondary HST travel switch (6) Horn switch (20) Max. traction switch (7) Lamp switch (21) PCS (Proportional Control Switch) (if equipped) (7) Turn signal lever...
Page 150 EXPLANATION OF COMPONENTS OPERATION CIGARETTE LIGHTER The cigarette lighter is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its origi- nal position after a few seconds, so pull it out to use it. If the cigarette lighter is removed, the socket can be used as an 85 W (24 V x 3.5 A) power supply.
Page 151 OPERATION EXPLANATION OF COMPONENTS HORN SWITCH If you press the horn switch, the horn sounds. TRAVEL SPEED CONTROL DIAL The travel speed control dial is used to freely set the maximum travel speed at the 1st speed range. By turning the dial clockwise, the setting of maximum travel speed becomes higher, and by turning the dial counterclock- wise, the setting becomes lower.
Page 152 If the parking brake was used as a secondary brake when the machine was traveling at high speed, ask your Komatsu distributor for inspection of the parking brake system. The parking brake switch is used to apply the parking brake.
Page 153 OPERATION EXPLANATION OF COMPONENTS REAR WIPER SWITCH When turning the lever (E) of the rear wiper switch, the rear wiper operates. Position (A): Washer fluid is sprayed out. When you release your hand, it returns to position (B). Position (B): (OFF) Wiper is stopped. Position (C): Wiper operates intermittently.
Page 154 Slightly operate the bucket toward DUMP side to release it from the stopper of the boom, and then the effect of the ECSS increases. • To adjust the travel speed of when it is operated or not, consult your Komatsu distributor. 3-90...
Page 155 OPERATION EXPLANATION OF COMPONENTS FRONT WORKING LAMP SWITCH WARNING The working lamps must be turned off when the machine is traveling on a public road. Use the front working lamp switch to light up the front working lamps. Position (A): The working lamps light up. Position (B): The working lamps go out.
Page 156 EXPLANATION OF COMPONENTS OPERATION 2-STAGE LOW IDLE SWITCH Pressing the 2-stage low idle switch increases the engine idle speed. Position (A): ON Position (B): OFF REAR HEATED WIRE GLASS SWITCH When pressing the switch for rear window glass with heated wire, the rear heated wire glass is turned on to clear the glass.
Page 157 OPERATION EXPLANATION OF COMPONENTS The work equipment is locked (the pilot lamp lights up) or un- locked (the pilot lamp goes out) each time you press the posi- tion (B) of the switch. If you release your hand from the switch, it automatically re- turns to its original position.
Page 158 EXPLANATION OF COMPONENTS OPERATION If the machine cannot travel due to the trouble in the DEF system, operate the directional lever to F (FOR- WARD) or R (REVERSE) position while holding the switch in position (B), and the machine travels forward and reverse at low speed.
Page 159 OPERATION EXPLANATION OF COMPONENTS When the S mode is actuated, tires will not easily slip and operation on a very slippery ground such as a snow removal work can be performed easily, because an appropriate driving force is obtained. Moreover, the machine may start smoothly and a sudden start at forward travel may not occur. REMARK •...
Page 160 EXPLANATION OF COMPONENTS OPERATION Traction control operating state Features Traction control Switch position Display on monitor Target material of setting Rim pull Road conditions loading Suitable on the Suitable for heavy ground not slip- Large target material. pery. (*1) ↑ ↑...
Page 161 OFF position but the engine does not stop. • Use the engine shutdown secondary switch only in an emergency. Contact your Komatsu distributor for repair immediately when there is any abnormality on this switch. • If the engine shutdown secondary switch is set to STOP ENGINE position by mistake while the ma- chine is operating normally, “Engine Shutdown Secondary SW in Operation”...
Page 162: Control Levers And Pedals
EXPLANATION OF COMPONENTS OPERATION Raise cover (1) and open it. There is a switch under the cover. Pull up the switch, and the engine stops. (a) STOP ENGINE: When abnormal (switch is set up) (b) NORMAL: When normal (switch is set down) •...
Page 163 OPERATION EXPLANATION OF COMPONENTS (3) Multifunction mono-lever (5) Brake pedal (4) Accelerator pedal DIRECTIONAL LEVER The directional lever switches the machine travel between the forward and reverse. The engine does not start if the directional lever is not in NEU- TRAL position (N).
Page 164 0 to 162 mm NOTICE Do not operate the steering tilt lock lever repeatedly with an excessive force. The lever can be loosened or its angle can be displaced. In such case, ask your Komatsu distributor for inspection. BRAKE PEDAL WARNING •...
Page 165: Other Equipment
OPERATION EXPLANATION OF COMPONENTS NOTICE Frequent braking increases the axle oil temperature. As a result, the alarm buzzer may sound and the warning lamp may light up for protection of the brake discs. Observe the following ways of operation to prevent the increase of the axle oil temperature.
Page 166 EXPLANATION OF COMPONENTS OPERATION CAB DOOR HANDLE While the key is not in the lock position, pull right side (1) of the door handle with the right hand, and push left side (2) with the thumb, and the door opens to the full open position, OPEN HANDLE FOR CAB L.H.
Page 167 OPERATION EXPLANATION OF COMPONENTS UNLOCK KNOB FOR SLIDE WINDOW OF CAB Use this to open and close the door window glass up and down. Grip unlock knob (1) to release the lock, then move it to the lower LOCK position and release it. There are 3 stages for LOCK position (A).
Page 168 EXPLANATION OF COMPONENTS OPERATION Pull up door knob (1). Hold door knob (1) and pull it toward the rear of the ma- chine. Remove the guide rail of the door knob from guide pin (2) fixed to the cab and unlock the right side door. Open the right side door wide and go out.
Page 169 OPERATION EXPLANATION OF COMPONENTS NOTICE If the door is closed without holding door knob (1), the plastic part of the door knob hits against guide pin (2) on the cab side and may be broken. Always close the door while holding door knob (1). CAP AND COVER WITH LOCK Use the starting switch key to open and close the locks on the caps and covers.
Page 170 EXPLANATION OF COMPONENTS OPERATION ASHTRAY This is on the right side of the operator's seat. Always extinguish your cigarette before putting it in the ashtray and be sure to close the lid. NOTICE While removing the ashtray, if it is stuck in the console cover and hard to be removed, open lid (A) of ashtray, then hold the ashtray body (B) and twist it to remove.
Page 171 OPERATION EXPLANATION OF COMPONENTS NOTICE • A stereo miniature plug can be connected. • As a power source, use the battery attached to the equipment to connect. If you use an electric power supply installed to the machine, the noise may occur. •...
Page 172 EXPLANATION OF COMPONENTS OPERATION Fuse capacities and circuit names Fuse box A Fuse Name of circuit capacity 20 A Starting switch 10 A Hazard lamp 15 A 30 A Engine control 10 A Monitor panel 15 A Radio/ Room lamp 10 A Spare 10 A L.H. headlamp 10 A R.H.
Page 173 OPERATION EXPLANATION OF COMPONENTS Fuse box C Fuse Name of circuit capacity 20 A Smart sensor 10 A Smart sensor 10 A DEF heater 20 A DEF heater SLOW-BLOW FUSE NOTICE When replacing the slow-blow fuse, be sure to turn the starting switch to OFF position and, after con- firming that the system operating lamp is not lit, set the battery disconnect switch key to OFF position.
Page 174 EXPLANATION OF COMPONENTS OPERATION FRAME LOCK BAR WARNING • When performing the maintenance or transporting the machine, always set the frame lock bar to LOCK position. • When driving the machine, always set the frame lock bar to FREE position. If the frame lock bar is not in FREE position, the steering becomes inoperative and this may lead to serious personal injury or death.
Page 175 OPERATION EXPLANATION OF COMPONENTS Fold the handle (4) of towing pin (1) to lock. When removing it, perform the procedure in the reverse or- der. GREASE PUMP HOLDER The grease pump is inside the engine side cover on the right side of the machine.
Page 176 EXPLANATION OF COMPONENTS OPERATION Open the cover (1) of the battery box on the rear right of the machine, raise the rubber cover (2), and battery disconnect switch (3) is seen. (O): OFF position It allows inserting and removing of the switch key (3), and is used for cutting off the current from the battery.
Page 177 • After the starting switch has been turned off, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. • While DEF system devices are operating, the system operating lamp lights up to return DEF to the tank.
Page 178 • Do not operate the engine without the KCCV filter ele- ment or use a filter element other than the Komatsu genuine one. If this is ignored, the engine sucks oil and foreign ma- terial which can cause a trouble.
Page 179 Urea SCR systems. Alerts in Induce- ment of the Komatsu Urea SCR System progress step by step. It starts with visual indications on the machine monitor with audible sounds to engine power deration to avoid dangerous conditions.
Page 180 EXPLANATION OF COMPONENTS OPERATION Press the menu switch on the standard screen to display “Aftertreatment Devices Regeneration” screen of the user menu. Low-level requirement for regeneration • When caution lamp (2) comes on in yellow (action level (3): “L01”), screen (A) is displayed first. •...
Page 181 OPERATION EXPLANATION OF COMPONENTS High-level requirement for regeneration • When caution lamp (2) and action level: “L03” comes on in red (3). • If the machine is stopped completely, the screen changes to the “Aftertreatment Devices Regeneration” screen (C) after 3 seconds. Then, the “Aftertreatment Devices Regeneration”...
Page 182 EXPLANATION OF COMPONENTS OPERATION Press the menu switch to display “Aftertreatment Devices Regeneration” screen. Select the manual stationary regeneration, check again safety of the surrounding area and make sure the area is free from irrelevant people or combustible material, then press ENTER switch. If the machine needs to be moved again to secure safety, move it to a safe place and repeat the procedure from step 1.
Page 183 OPERATION EXPLANATION OF COMPONENTS This screen is displayed during the manual stationary re- generation. It may take more than 40 minutes to complete the manual stationary regeneration. Do not touch any switch on the screen or accelerator pedal until the regener- ation is completed and the standard screen is displayed again.
Page 184 EXPLANATION OF COMPONENTS OPERATION Select Regeneration Disable and press ENTER switch. The regeneration function is disabled and the regeneration is not performed. • When the regeneration is disabled, aftertreatment devices regeneration disable pilot lamp (1) is displayed with hatch on the standard screen. •...
Page 185 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR CANCELING AFTERTREATMENT DEVICES REGENERATION DISABLE CAUTION Before you start regeneration again, move the machine to a safe area first. Release the accelerator pedal, set the directional lever in NEUTRAL position (N), and the parking brake switch to “ON”...
Page 186 EXPLANATION OF COMPONENTS OPERATION Short duration of white plume given off from the tail pipe may be visible at and shortly after engine start-up in cold weather, but this is not malfunction. INDUCEMENT STRATEGY WHEN THE DEF TANK LEVEL BECOMES LOW When the amount of DEF in the tank goes low, the Inducement strategy will be activated.
Page 187 OPERATION EXPLANATION OF COMPONENTS Status of Inducement (4): “1 DEF low level warning ap- pears.” Add DEF to the DEF tank immediately. • Continuous Warning: The audible alert sounds in repetition of “Intermittent alarm”. 2 gradations of the DEF level gauge light up in the red range.
Page 188 “L04 (Severe Inducement)” is displayed. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Infor- mation” screen of the user menu.
Page 189 OPERATION EXPLANATION OF COMPONENTS Perform the following procedure. Press the menu switch on the standard screen to display the “SCR Information” screen of the user menu. After a lapse of 3 seconds to stop the machine, “SCR Informa- tion” screen is displayed. “SCR Information”...
Page 190 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen message (4): “2 Without treat- ment, engine power will be derated.” Move the machine to the safe place and contact your Ko- matsu Distributor. The duration of “Continuous Warning” is 5 hours. The re- maining time (Hours and Minutes) to “Low level Induce- ment”...
Page 191 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Low level Inducement”.
Page 192 EXPLANATION OF COMPONENTS OPERATION • Warning: The audible alert sounds in “Intermittent alarm”. The Engine system caution lamp (1) lights up in red. The action level “L03” lights up in red at action level dis- play (3). Press the menu switch to display the “SCR Information” screen.
Page 193 “Temporary Restoration from Inducement” in this manual. If Inducement advances to “Severe In- ducement” and it becomes necessary to restore engine power, use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor. TEMPORARY RESTORATION FROM INDUCEMENT Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea SCR systems.
Page 194 EXPLANATION OF COMPONENTS OPERATION Press the menu switch (1) to display the “SCR Information” screen when the Standard screen is on, only when the Urea SCR system is in “Severe Inducement”. Press the enter switch (2) to display the menu windows popping up in the bottom half of the “SCR Information”.
Page 195 OPERATION EXPLANATION OF COMPONENTS Press the enter switch (2) while the “Engine power Recov- ery” window is displayed. Temporary Restoration from Inducement is activated and engine power deration is relieved to the deration of “Low level Inducement” for the maximum of 30 minutes. The remaining time (minutes/seconds) of “Temporary Re- storation from Inducement”...
Page 196 2000 hours. • If the machine is operated without DEF filter attached, or with the filter other than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine. Never operate the machine without DEF filter attached, nor use the filter other than Komatsu genuine parts.
Page 197 It can be useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma- chine information for supply of service to the customers, improvement of our products and service, etc.
Page 198: Machine Operations And Controls
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. If the machine is inclining, make it level before checking.
Page 199 OPERATION MACHINE OPERATIONS AND CONTROLS 11. Check the HST piping, transfer case, axle, hydraulic tank, hoses, and joints for oil leakage. Check for oil leakage. If any problem is found, repair the place where the oil is leaking. 12. Check brake line for oil leakage. Check for leakage of oil or damage to the hoses and tubes.
Page 200 If any problem is found, replace the part. 23. Check the rearview monitor. Check the rearview monitor for problem. If it is failed, ask your Komatsu distributor for repair. METHOD FOR CHECKING BEFORE STARTING Always check the items in this section before starting the engine each day.
Page 201 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDI- MENT WARNING • Immediately after the engine is stopped, all of parts are still very hot. Avoid draining water or re- moving the transparent cup. Wait for all parts to cool down before starting the work. •...
Page 202 MACHINE OPERATIONS AND CONTROLS OPERATION When fuel starts to be drained from drain hose (5), tighten plug (6) immediately to stop draining. Tightening torque: 0.2 to 0.45 Nm {0.02 to 0.046 kgm} REMARK • On this machine, a sensor is installed to detect if water accumulates in transparent cup (3). When the water separator caution lamp (4) lights up in red on the machine monitor, it indicates that water is accumulated in transparent cup (3).
Page 203 OPERATION MACHINE OPERATIONS AND CONTROLS Open the engine side cover (1) on the left side of the ma- chine. Check the reservoir tank (2). Check that the coolant level is between FULL and LOW marks of the reservoir tank (2). If the coolant is insufficient, add the coolant to FULL level through the filler port of the reservoir tank (2).
Page 204 MACHINE OPERATIONS AND CONTROLS OPERATION Pull out the dipstick (G) and wipe the oil off with a cloth. Fully insert the dipstick (G) into the dipstick pipe, then pull it out. If the oil level is between marks H and L, it is correct. If the oil level is below L mark, add oil through oil filler port (F).
Page 205 • If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause of it and to perform the repair. • Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap with water to clear the vent hole.
Page 206 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE When restarting the engine that has stopped because of running out of fuel, all air must be sufficiently bled from the circuit. For the method of bleeding air, see “PROCEDURES FOR BLEEDING AIR FROM FUEL CIRCUIT”. Take care not to cause engine stall because of running out of fuel.
Page 207 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the audible alert sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and for inspection. DEF injector and/or DEF pump may need to be replaced.
Page 208 MACHINE OPERATIONS AND CONTROLS OPERATION Set the frame lock bar (2) to LOCK position (L). Open up cover (3) at the right side of the machine, clean blue DEF tank filler cap (4) and surrounding area. Turn the cap (4) counterclockwise. The caps of DEF tanks are blue, as required by emission regulations.
Page 209 If the fluid does not spout out normally, clean the washer nozzle hole with a fine wire such as a safety pin. • If the condition does not become normal, ask your Komatsu distributor to perform inspection and repair. METHOD FOR CHECKING WIPER FUNCTION Operate the wiper in the “Intermittent”, “Low”, and “High”...
Page 210 • Operate the rear heated wire glass switch and check that the rear glass surface is heated properly. If there is any abnormality, ask your KOMATSU distributor for testing and repair. METHOD FOR CHECKING LOCKS Check that all places can be locked properly.
Page 211 OPERATION MACHINE OPERATIONS AND CONTROLS Pull the lever upward, and move the backrest forward or backward. Sit with your back against the backrest when adjusting. If your back is not on the backrest, it may suddenly return to the original position. Adjustment amount Forward tilt: 21 °(any degree is acceptable if it is greater than 21 °.)
Page 212 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING SEAT CUSHION IN FORE-AFTER DIRECTION Operate the lever upward, set the seat cushion to the desired position, then release the lever. Fore-aft adjustment: 60 mm METHOD FOR ADJUSTING HEADREST ANGLE Move the headrest back and forth to set it to the desired angle. Adjustment amount: 30 °...
Page 213 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING LUMBAR SUPPORT Turn the knob to the right or left, and give proper tension to the waist part. METHOD FOR ADJUSTING SUSPENSION DAMPER HARDNESS By operating the knob, the damping force of the suspension damper can be adjusted. •...
Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR WARMING UP SEAT When the switch is operated in the (A) direction, the heater in- side the seat cushion is activated. When it is operated in the (B) direction, the heater is turned off. When the heater is being operated, the lamp inside the switch lights up.
Page 215 Tightening torque of mirrors (A) and (B): 2.0 to 2.5 Nm {0.2 to 0.25 kgm} • If the torque cannot be controlled, ask your Komatsu distributor for adjustment. Mirrors (A), (B) Loosen bolt (1) of the mirror, then adjust the mirror to a position which gives the best view from the operator's seat of the blind spot at the right and left sides of the rear of the machine.
Page 216 If you try to work standing on the counterweight, there is a danger of serious injury or death due to falling off from the machine. • Install only the Komatsu genuine camera. Adjust the angle of the rear view camera so that people within 1 m away from the machine's rear part (W) is displayed in the monitor at the operator's seat.
Page 217 OPERATION MACHINE OPERATIONS AND CONTROLS Loosen mounting bolts (1) (3 places) and adjust angle (A). REMARK A part of the machine is shown on the monitor screen. After adjusting, tighten bolts (1) (3 places). 3-153...
Page 218 (D) matches to position (B) that is 1.5 m away from the rear end of the machine. When the reference line is abnormal, change its setting to Non- display and contact your Komatsu distributor. METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING •...
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR FASTENING SEAT BELT Sit in the seat and depress the brake pedal fully. Under this condition, adjust the seat so that your back is fitted to the backrest. Sit on the seat, pull the belt on right side, then insert tongue (1) into buckle (2) until a click is heard.
Page 220 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING When starting the engine, check that the work equipment is securely locked (the pilot lamp in the switch is lit). If the multifunction mono-lever is touched by accident when starting the engine, the work equipment may move unexpectedly, and this may lead to a serious injury or death.
Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS Check that the directional lever (2) is in NEUTRAL position (N). REMARK The engine can be started only when the directional lever is in NEUTRAL position (N). When the directional selector switch actuation switch (3) is in ON position (A), check that the directional selector switch (4) is in NEUTRAL position (N).
Page 222: Method For Starting Engine
The engine tachometer swings once. If the monitor does not light up, there may be a failure or wire breakage. Ask your Komatsu distributor for inspection. Check that the work equipment is locked (the pilot lamp in the switch (6) is lit).
Page 223 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key in starting switch (1) to ON position (B). When the ambient temperature is low, preheating pilot lamp (2) lights up and automatic preheating is performed. Keep the starting switch key (1) at ON position until pre- heating pilot lamp (2) goes out.
Page 224 MACHINE OPERATIONS AND CONTROLS OPERATION START IN COLD WEATHER WARNING • Start the engine only while sitting on the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may cause a fire or serious personal injury or death. •...
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS After preheating pilot lamp (2) goes out, turn starting switch key (1) to START position (C). Keep the key in starting switch (1) at position (C) to keep running the starting motor until the engine starts. The starting motor keeps running to start the engine.
Page 226: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 227 Drive the machine forward and in reverse slowly on a level ground with no obstacles around and check the brake performance. If any problem is found in operation of the brake, ask your Komatsu distributor for adjustment. METHOD FOR CHECKING CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR Depress the brake pedal fully and check that the pedal is not too close to the floor.
Page 228 MACHINE OPERATIONS AND CONTROLS OPERATION Depress the accelerator pedal (1) lightly and run the en- gine at a medium speed for approximately 5 minutes with no load. Only in cold weather, perform the following operation to warm up the hydraulic oil. Check that the engine rotation is smooth, then cancel the work equipment lock (turn off the pilot lamp in the switch) with the work equipment lock switch (2) after the warm-up...
Page 229: Method For Stopping Engine
(3) and HST oil temperature gauge (4) indicate the green range. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distribu- tor. REMARK The cooling fan speed varies according to the following conditions, but it is not abnormal.
Page 230: Method For Starting Machine (Travel Forward And Reverse, And Shifting Gear) And Stopping Machine
MACHINE OPERATIONS AND CONTROLS OPERATION Turn the key of starting switch (1) to OFF position (A), and stop the engine. Remove the key from starting switch (1). REMARK • After the engine is stopped, DEF in DEF injector and pump is automatically purged and returned to the tank to prevent malfunction of the devices caused by freez- ing of DEF or deposition of urea.
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS Check that the caution lamp (1) is not lit. Check that the multifunction mono-lever (2) is in “HOLD” position. Cancel the work equipment lock (the pilot lamp in the switch goes out) with the work equipment lock switch (3). Operate the multifunction mono-lever (2) to set the work equipment to the travel posture as shown in the figure.
Page 232 Position (R): REVERSE Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does not sound, ask your Komatsu dis- tributor for repair. REMARK You can also use the directional selector switch (7) to set the travel direction to FORWARD, NEUTRAL, and RE- VERSE.
Page 233 OPERATION MACHINE OPERATIONS AND CONTROLS Release the R.H. brake pedal (4), then depress the accel- erator pedal (9) to move off. METHOD FOR SELECTING SPEED RANGE WARNING Avoid an abrupt shifting of the speed range while traveling at high speed. Reduce the speed by releas- ing the accelerator pedal always before selecting the speed range.
Page 234 Position (R): REVERSE Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does not sound, ask your Komatsu distribu- tor for repair. REMARK If you operate the directional lever slowly or stop it at midway between the lever positions, the centralized warning lamp may light up and the alarm buzzer may sound.
Page 235 OPERATION MACHINE OPERATIONS AND CONTROLS Directional selection by switch operation WARNING When shifting the directional lever (1) to FORWARD (F) or REVERSE (R) position while the directional selector switch actuation switch (3) is in ON position, the machine travels forward or in reverse in accordance with the directional lever (1) regardless of the position of the directional selec- tor switch (2).
Page 236 MACHINE OPERATIONS AND CONTROLS OPERATION Set the directional selector switch (2) to FORWARD (F) or REVERSE (R) position. REMARK When shifting the directional lever (1) to FORWARD (F) or REVERSE (R) position while the directional se- lector switch actuation switch (3) is in ON position, the machine travels forward or in reverse in accordance with the directional lever (1) regardless of the position of the directional selector switch (2).
Page 237 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STOPPING MACHINE WARNING • Stop the machine gradually. Avoid a sudden stop. • Do not park the machine on a slope. If it is unavoida- ble to park the machine on a slope, place the machine at a right angle to the slope face, lower the bucket to the ground, and then chock the tires to prevent the machine from moving.
Page 238: Method For Steering Machine
MACHINE OPERATIONS AND CONTROLS OPERATION Set the directional lever (3) and the directional selector switch (4) to NEUTRAL (N) position. Set the parking brake switch (5) to ON position (A), and apply the parking brake. REMARK Applying the parking brake automatically sets the travel system to NEUTAL.
Page 239 Check that the play (a) of steering wheel is 50 to 100 mm, and that the operation of steering wheel is normal. If any problem is found, ask your Komatsu distributor for inspection. HANDLE SECONDARY STEERING SYSTEM...
Page 240: Method For Operating Work Equipment
MACHINE OPERATIONS AND CONTROLS OPERATION If the steering oil pressure caution lamp (red) (3) lights up, move the machine immediately to a safe place and stop it there. Do not operate the machine until the cause is identified and it is repaired. REMARK When engine is running at low speed and when you use some hydraulic system functions, the steering low oil pressure pilot pump (red) (2) may light up temporarily.
Page 241: 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 was used as a secondary brake, ask your Komatsu distributor to inspect the park- ing brake system for any trouble.
Page 242 • The most suitable tire pressure and travel speed differ according to the tire type and condition of the travel surface. Contact your Komatsu distributor or tire dealer. • The following shows the appropriate tire inflation pressure and travel speed when the machine is equipped with the standard tires (20.5R25☆) and runs on the paved surface.
Page 243: Method For Adjusting Work Equipment Posture
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING WORK EQUIPMENT POSTURE WARNING • Place the machine on a level ground and move the parking brake switch from OFF position (B) to ON po- sition (A) with the brake pedal depressed to apply parking brake securely, and then confirm that the ma- chine is stopped completely.
Page 244 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING BUCKET POSITIONER Lower the bucket to the ground. Return the multifunction mono-lever to “HOLD” position ac- cording to the desired digging angle. Press the work equipment lock switch and lock the work equipment (the pilot lamp is lit).
Page 245: Recommended Applications
OPERATION MACHINE OPERATIONS AND CONTROLS Loosen the nut (1), and adjust the position of proximity switch (3) so that the rear end (A) of the bar (2) is matched to the center of sensory surface (B) of the proximity switch (3).
Page 246 MACHINE OPERATIONS AND CONTROLS OPERATION DIGGING WORK WARNING • Never perform the digging or scooping operation with the machine articulated. There is a danger that the machine may tip over. • Never perform the boom RAISE operation with the machine articulated and the bucket full. There is a danger that the machine may tip over.
Page 247 OPERATION MACHINE OPERATIONS AND CONTROLS When it is hard to thrust the bucket into the stockpile, move the bucket edge upward and downward by shifting the multifunction mono-lever to the right and left . DIG AND LOAD ON HORIZONTAL SURFACE •...
Page 248 If this is not done, the tires will be damaged. Consult your Komatsu distributor or tire dealer. The load and carry method for wheel loaders consists of a cy- cle of scooping → hauling → loading (into a hopper, glory hole etc.).
Page 249 OPERATION MACHINE OPERATIONS AND CONTROLS WARNING • Maintain the ground of job site level. Do not perform sudden steering or braking while the boom is being raised with the bucket loaded. This is dangerous. • Never thrust the work equipment into the target material (soil or crushed rock) when the machine is traveling at high speed.
Page 250: Method For Parking Machine
MACHINE OPERATIONS AND CONTROLS OPERATION V-SHAPE LOADING Park a dump truck at an angle of approximately 60 ° to the scooping direction of the wheel loader. After scooping the soils, back the wheel loader in such direction that it is at a right angle to the dump truck and then move the machine forward to load the soils onto the dump truck.
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS Release the accelerator pedal (1), then depress the brake pedal (2) to stop the machine. The machine stops. Set the directional lever (3) and the directional selector switch (4) to NEUTRAL (N) position. Move the parking brake switch (5) to ON position (A) while depressing the brake pedal, to apply the parking brake.
Page 252: Method For Checking After Finishing Work
If oil or coolant leakage or any abnormality is detected, repair it. Check DEF tank, pump, injector, hose, and joint for leakage. If any abnormality is found, ask your Komatsu distributor for repair. Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP PROCEDURES FOR OPENING FUEL FILLER PORT CAP Insert the starting switch key into the key slot. Turn the starting switch key to “OPEN” position (A), and then align the key slot with match mark (1) of the cap.
Page 254: Handle Tire
Do not to use tires, such as urethane tires, that weigh remarkably more than the standard tires since the machine can be damaged due to an unexpected load. • If a tire not specified by Komatsu is used, rim displacement may occur between the tire and rim. Operator comfort may be degraded as well. 3-190...
Page 255 (5) Bead (6) Inner liner (7) Cord Contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. TIRE PRESSURE Check the tire inflation pressure before driving, when the tires are cool.
Page 256 When traveling continuously in load-and-carry operation, choose the appropriate tires to match the operating conditions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged. Consult your Komatsu distributor or tire dealer. 3-192...
Page 257: Handle Air Conditioner
To allow the air conditioner to show its full performance, have inspection and maintenance performed peri- odically. When adding refrigerant or performing other maintenance, special tools and instruments are nee- ded, so ask your Komatsu distributor to perform inspection and maintenance. •...
Page 258: Explanation Of Air Conditioner Equipment
HANDLE AIR CONDITIONER OPERATION EXPLANATION OF AIR CONDITIONER EQUIPMENT (1) OFF switch (6) FRESH/RECIRC air selector switch (2) Auto switch (7) Vent selector switch (3) Air conditioner switch (8) Defroster switch (4) Fan switch (9) Display monitor (5) Temperature control switch Air conditioner monitor (A) Air flow bar (E) Vent display...
Page 259 OPERATION HANDLE AIR CONDITIONER • During auto operation, the air flow is automatically adjusted. The set position of the air flow is indicated on the display monitor. Monitor display Air flow Air flow “LOW” Air flow “MEDIUM 1” Air flow “MEDIUM 2” Air flow “MEDIUM 3”...
Page 260 HANDLE AIR CONDITIONER OPERATION VENT SELECTOR SWITCH In the manual operation, use the vent selector switch to select the vents. • There are 4 modes of vents: FACE, FACE/FOOT, FOOT, and FOOT/DEF. (DEF is selected only when the defroster switch is pressed.) •...
Page 261 OPERATION HANDLE AIR CONDITIONER AUTO SWITCH Use auto switch for automatic selection of the air flow and vents according to the set temperature. This switch is also used as the main switch of the air condition- • When AUTO switch is pressed, AUTO on the display moni- tor lights up to indicate that the air conditioner is in the au- tomatic mode.
Page 262 HANDLE AIR CONDITIONER OPERATION DISPLAY MONITOR The display monitor displays the state of air flow (A), operation of air conditioner (B), set temperature (C), FRESH/RECIRC air (D), vents (E), automatic operation (F), and defroster (G). AIR CONDITIONER SWITCH Use the air conditioner switch to start and stop the cooling, heating, or drying function.
Page 263: Method For Operating Air Conditioner
OPERATION HANDLE AIR CONDITIONER DEFROSTER SWITCH The defroster switch is used to set the vents in the defroster mode. • Use this mode to clear the front glass mist, etc. • When the defroster switch is pressed during automatic op- eration, AUTO on the air conditioner monitor goes out and the defroster mark is displayed.
Page 264 HANDLE AIR CONDITIONER OPERATION Press (A) or (B) of the temperature control switch to set to the desired temperature. The air flow and combination of the vents are automatically selected according to the set temperature, and the air con- ditioner is operated automatically to provide the set tem- perature.
Page 265 OPERATION HANDLE AIR CONDITIONER Turn the air conditioner switch ON. At this time, the air conditioner operation mark lights up on the display monitor. Press (A) or (B) of the temperature control switch to adjust the temperature in the cab. REMARK The air temperature is so adjusted that the temperature in the cab becomes the set temperature when the set tem-...
Page 266 HANDLE AIR CONDITIONER OPERATION METHOD FOR OPERATING DEFROSTER Frost adhered to the outside of the window glass can be removed by defroster operation. Press the defroster switch to set the vents in DEF mode. Press FRESH/RECIRC air selector switch and set it to RE- CIRC mode.
Page 267: Transportation
OPERATION TRANSPORTATION TRANSPORTATION TRANSPORTATION PROCEDURE When transporting the machine, choose the transportation method in reference to the weight and dimensions shown in “SPECIFICATIONS”. Note that the “SPECIFICATIONS” (weight and dimensions) vary depending on the type of tire and bucket. LOADING AND UNLOADING WITH TRAILER WARNING •...
Page 268 TRANSPORTATION OPERATION Press the work equipment lock switch (1) and lock the work equipment (the pilot lamp in the switch is lit). Move the parking brake switch (3) from OFF position (B) to ON position (A) with the brake pedal (2) depressed to ap- ply the parking brake securely.
Page 269 OPERATION TRANSPORTATION Securing position 3-205...
Page 270 TRANSPORTATION OPERATION Fixing angle (A) : 71 ° (B) : 64 ° (C) : 35 ° (D) : 44 ° Expected trailer width (E) : 2990 mm The fixed load per 1 piece Front frame: 93000 N {9480 kg} Rear frame: 118000 N {12030 kg} REMARK When putting the chains or wire ropes to the tie down hole, you may open the engine side cover (4) to perform the work.
Page 271: Method For Lifting Machine
OPERATION TRANSPORTATION Set the frame lock bar to FREE position (F). Start the engine. Warm up the engine fully in cold weather. Check that the multifunction mono-lever is in “HOLD” posi- tion. Press the work equipment lock switch (6) and unlock the work equipment lock (the pilot lamp in the switch is not lit).
Page 272 This method of lifting applies to the standard specification machine. The method of lifting differs depending on the attachments and options installed. For the procedure for the machine with other than standard specification, consult your Komatsu distrib- utor. For the weight, see “SPECIFICATIONS”.
Page 273 OPERATION TRANSPORTATION Use the lifting tools such as the wire rope and sling suita- ble for the weight of the machine as shown in the figure of the lifting position. Reeve the wire rope to the lifting posi- tions of the machine. NOTICE •...
Page 274: Cold Weather Operation
When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 275: Precautions After Daily Work Completion In Cold Weather
OPERATION COLD WEATHER OPERATION BATTERY WARNING • Battery generates flammable gas. Never bring any open flame near fuel. • Battery electrolyte is dangerous object. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor. •...
Page 276: After Cold Weather Season
Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by repeated freeze, ask your Komatsu distributor to inspect. 3-212...
Page 277: Precautions For Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, perform the following items before using it. •...
Page 278 If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement. Dispose of drained DEF according to the local regulations and rules.
Page 279: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS ACTIONS WHEN RUNNING OUT OF FUEL WARNING When starting the engine again, check safety around the engine thoroughly, and then crank the engine. When starting the engine again after running out of fuel, fill with fuel, and bleed the air from the fuel system before starting the engine.
Page 280: Precautions For Towing Machine
For the allowable towing capacity for this machine, see “SPECIFICATIONS”. • For the procedure for towing a disabled machine, consult your Komatsu distributor. This machine must not be towed except in emergencies. However, if it is avoidable to tow the machine, take the following precautions.
Page 281 The speed range is selected by electric signals in normal operation. If there should be a failure in the electrical system, and the machine does not move, ask your Komatsu distributor. NOTICE If an emergency travel operation is needed, ask your Komatsu distributor to perform it. 3-217...
Page 282: Precautions For Discharged Battery
TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch and battery discon- nect switch keys to OFF positions.
Page 283 OPERATION TROUBLES AND ACTIONS When replacing the battery, perform the positioning of the battery by putting its side face to the cushions (A) and (B). If the battery positioning is not performed, the battery may move during operation, and there will be a danger that loosening of terminal and sparks may occur.
Page 284 TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, it is dangerous that the battery may explode. Al- ways follow the instructions in “PRECAUTIONS FOR DIS- CHARGED BATTERY” and the instruction manual accom- panying the charger, and observe the following.
Page 285 OPERATION TROUBLES AND ACTIONS START ENGINE WITH JUMPER CABLES WARNING • Never connect the positive (+) and negative (-) termi- nals when connecting the cables. • Wear the protective eyeglasses and rubber gloves al- ways when starting the engine by using the jumper ca- ble.
Page 286: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 287 Replace. (*) PHENOMENA AND ACTIONS FOR CHASSIS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. 3-223...
Page 288 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Parking brake is applied. Release the parking brake. Directional lever is not shifted in posi- Shift the lever completely in position. tion completely. Engine runs but machine does not There is no electric current in the di- Check the fuse and wiring harness move.
Page 289 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. 3-225...
Page 290 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Engine oil pressure caution lamp Lowered oil level in engine oil pan Set oil to specified level. See lights up. (sucking in air) CHECKS BEFORE STARTING. Improper oil is used. (Viscosity is im- Replace oil.
Page 291 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Starting motor turns but engine does Add fuel. See CHECKS BEFORE Lack of fuel not start. STARTING. Air in fuel system Repair portion where air is sucked in. Fill filter with fuel. See EVERY 500 Fuel filter is not filled with fuel.
Page 292 REMARK If no point of contact telephone number is registered, no tele- phone number is displayed. Ask your Komatsu distributor for the telephone number regis- tration if necessary. 3-228...
Page 293: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 294: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 295: Dusty Jobsites
MAINTENANCE PRECAUTIONS FOR MAINTENANCE DUSTY JOBSITES When working at dusty jobsites, observe the following. • Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not to let the fins become clogged. • Replace the fuel filter more frequently.
Page 296: Close Engine Side Cover Securely
PRECAUTIONS FOR MAINTENANCE MAINTENANCE For details, see “METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. CLOSE ENGINE SIDE COVER SECURELY When closing the engine side cover after inspection and maintenance, lock it securely with the catcher. If the engine side cover is not locked with the catcher, the engine side cover may open.
Page 297: Outline Of Maintenance
OUTLINE OF MAINTENANCE OUTLINE OF MAINTENANCE • Komatsu recommends using Komatsu genuine parts for replacement parts, grease or oil. • When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all the old oil and fill completely with the new oil.
Page 298 Always use ultra-low-sulfur diesel fuel. (≤10 ppm) The ASTM diesel fuel recommended by Komatsu may contain 5 % or less of biofuel. The EN diesel fuel may contain 7 % or less of it. Do not use any additive agent which includes metallic constituent.
Page 299 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 300 • When replacing oil filters, check if any metal particles are attached to the old filters. If any metal particles are found, consult your Komatsu distributor. • Do not open packages of spare filters until just before they are to be used.
Page 301: Handle Electrical Components
Komatsu recommends installing electric components specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. • When working at the seashore, keep the electrical component clean to prevent corrosion.
Page 302: Standard Tightening Torque 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, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 303 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Taper seal Tightening torque Nominal Thread size “a” Width across flats Target value Allowable range No. of hose (mm) “b” (mm) Nm kgm Nm kgm 34 to 63 3.5 to 6.5 59 to 98 6.0 to 10.0 10.5 84 to 132...
Page 304: Maintenance Schedule
See “MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED”. • Ask your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) ..........4-15 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ..........
Page 305: Maintenance Interval When Diesel Fuel Mixed With Bio-Fuel Is Used
MAINTENANCE MAINTENANCE SCHEDULE METHOD FOR LUBRICATING CENTER HINGE PIN ................4-64 METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS....4-64 METHOD FOR CHECKING AND REPLACING ALTERNATOR BELT............. 4-64 EVERY 2000 HOURS MAINTENANCE ......................4-64 METHOD FOR CHANGING OIL IN HYDRAULIC TANK ................. 4-64 METHOD FOR REPLACING HYDRAULIC OIL FILTER CARTRIDGE............
Page 306 MAINTENANCE SCHEDULE MAINTENANCE Maintenance interval after the diesel fuel has been changed to the diesel fuel mixed with bio-fuel Operating hours of the machine Service meter Every 500 hours Every 1000 hours 250 hours 500 hours Within 500 After 500 op- Within 500 After 500 op- When...
Page 307: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) Until first 100 hours operation, perform the following maintenance every 10 hours. • Lubrication of work equipment • Lubrication of steering cylinder pin For details of the method of replacement or maintenance, see EVERY 100 HOURS MAINTENANCE and EV- ERY 250 HOURS MAINTENANCE.
Page 308 MAINTENANCE PROCEDURE MAINTENANCE Open the engine side cover (1) on the right side of the ma- chine. Open the air cleaner inspection cover (2). Clean the element when the yellow piston shown in the dust indicator (3) display of the air cleaner enters the red (7.5 kPa {0.08 kg/cm }) position.
Page 309 MAINTENANCE MAINTENANCE PROCEDURE Clean the inside of the air cleaner body, cover (4) and va- cuator valve (7). NOTICE Do not clean and reuse the inner element. When re- placing the outer element, replace the inner element with a new one at the same time. When cleaning the element, do not tap it or hit it against something.
Page 310 MAINTENANCE PROCEDURE MAINTENANCE 12. Push the button of dust indicator (9). The yellow piston returns. 13. Close the air cleaner inspection cover (2). 14. Close the engine side cover (1) on the right side of the ma- chine. Even though the outer element has not been cleaned up to 6 times, if the yellow piston of dust indicator rises over 5 kPa {0.05 kg/cm } soon after the cleaning, replace both the inner and outer elements.
Page 311 MAINTENANCE MAINTENANCE PROCEDURE Pull out the outer element (5). Do not remove the inner element (6) at this time. Clean the interior of the air cleaner body, cover (4) and va- cuator valve (7) with a clean cloth, a whisk or others. Remove the inner element (6), then install the new inner element immediately.
Page 312: Method For Cleaning Inside Of Cooling System
The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 313 When handling the cooling water containing coolant that has been drained during changing the coolant or repairing the radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 314 MAINTENANCE PROCEDURE MAINTENANCE Place a container to catch the coolant under the drain hose (4). Open the drain valve (5) at the bottom of the radiator and drain the coolant. Close the drain valve (5). Pour the tap water through the filler port. Add water until it fills the radiator.
Page 315 MAINTENANCE MAINTENANCE PROCEDURE WARNING If you turn the steering wheel and stop turning it at certain position while the oil temperature is low, a time lag may result until the machine stops after the turning operation. In such case, set the frame lock bar to LOCK position (L) for safety and perform the warm-up operation in a large place.
Page 316: Method For Checking Oil Level In Transfer Case And Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE 20. Drain the coolant in reservoir tank (10). 21. Clean the inside of reservoir tank (10). 22. Add the Non-Amine Engine Coolant to the middle between FULL and LOW. 23. Stop the engine. 24. Approximately 3 minutes later, add the Non-Amine Engine Coolant up to the mouth of the coolant filler port.
Page 317 MAINTENANCE MAINTENANCE PROCEDURE While running the engine at low idle, remove the cap of oil filler port (F). Pull out the dipstick (G) and wipe the oil off with a cloth. Fully insert the dipstick (G) into the dipstick pipe, then re- move it.
Page 318: Method For Checking Oil Level In Axle Case And Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE • As a reference, check the marks (C) and (D) on dipstick (G) marked with “COLD STOP” side. • Stop the engine, and wait for 2 hours or longer before checking. • For the final oil level check, use “HOT IDLE” side of dip- stick (G) according to the preceding steps 1 to 8, after completing the warm-up operation of the transfer.
Page 319: Method For Cleaning Axle Breather
MAINTENANCE MAINTENANCE PROCEDURE Wipe off oil of dipstick (G) installed to plug (1) with a cloth. Set dipstick (G) as shown in the figure. (2): Axle (3): Spot facing surface Check the oil level. The level is appropriate if it is between 2 grooves (H) and (L) of the dipstick.
Page 320: Method For Cleaning Air Conditioner Condenser
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING AIR CONDITIONER CONDENSER WARNING • Do not use a steam cleaner for the cleaning since it is dangerous as the condenser is heated. • If the pressurized water hits a person directly or dirt scatters by use of it, there is a danger of per- sonal injury.
Page 321: Method For Cleaning Radiator Fin And Cooler Fin
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING RADIATOR FIN AND COOLER FIN WARNING • When the engine is running, do not open the engine side cover. When cleaning the fin, stop the en- gine rotation completely. • If compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by the compressed air, high-pressure water, or steam, there is a danger of personal injury.
Page 322 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING FINS WITH REAR GRILLE OPENED Open the rear grille (1). Push the lever (2) lightly to the right and open the fan guard (3). Blow off mud, dirt, leaves, etc. in radiator fins (4) with com- pressed air.
Page 323 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING FIN WITH ENGINE SIDE COVER OPEN Open the engine side covers (1) and (2) on the right and left sides of the machine. Remove the mounting bolts (4) of condenser (3) (2 places each on the right and left). Hold the top of the condenser (3) and tilt it toward front of the machine.
Page 324: Method For Inverting And Replacing Bolt On Cutting Edge
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR INVERTING AND REPLACING BOLT ON CUTTING EDGE WARNING It is dangerous if the work equipment moves by mistake when the cutting edge or end bit is being re- placed. Set the work equipment in a stable condition, stop the engine, then lock the work equipment (the pilot lamp in the switch lights up).
Page 325 Remove the tooth (1). REMARK If it cannot be removed by this method, for safety, ask your Komatsu distributor to have the replacement performed. Clean the bucket adapter (3) thoroughly. Install a new bucket tooth to the bucket adapter (3).
Page 326 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING KMAX TEETH (if equipped) Replace the tooth before the wear reaches to the adapter. Items to be prepared Socket wrench with 11 mm of width across flats and torque wrench REMARK The wear will become uniform by rotating the mounting position of the tooth. This will extend the service life of the tooth and reduce the frequency of replacement.
Page 327: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE MAINTENANCE PROCEDURE If the torque value is low, replace the pin with a new one. T1: Torque (Nm) T2: Turning angle (degree) REMARK The torque value increases gradually and reaches to the maximum at approximately 45 °, and it decreases gradually after 45 °.
Page 328: Method For Checking And Maintenance Air Conditioner
MAINTENANCE PROCEDURE MAINTENANCE Check the water level in window washer tank (2), and if it is insufficient, add the window washer fluid for automo- biles. Be careful not to let dirt or dust get in when adding it. After checking the fluid level, close the cover (1). METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...
Page 329 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR TESTING WHEN AIR CONDITIONER COMPRESSOR BELT IS RE- PLACED Press the middle point between the compressor pulley and drive pulley with your thumb (approximately 98 N {10 kg} ). The standard deflection is 8 to 11 mm. When you use a belt tension gauge, the tension is normal if it is in the range of 530 to 745 N {54 to 76 kg} . REMARK When the belt is replaced with a new one, the above value is employed as the initial tension since a stronger tension is required.
Page 330 MAINTENANCE PROCEDURE MAINTENANCE Start the engine and set the engine speed to approximate- ly 1500 rpm. Press the fan switch (1) and set the air flow to “MAX”. Press the temperature adjustment switch (2) and set the temperature to 18 °C. Fully open the doors and windows. Press the air conditioner switch (3) to turn on the air condi- tioner switch.
Page 331: Method For Replacing Slow-Blow Fuse
MAINTENANCE MAINTENANCE PROCEDURE Condition viewed through the State of refrigerant flow sight glass Milky white: Oil and refrigerant are separated and their mixture is milky white. MAINTENANCE AND SCHEDULE OF AIR CONDITIONER Maintenance schedule Check point Check items Check before op- 6 months inspec- Replacement in- eration...
Page 332: Method For Checking Function Of Ecss Accumulator
Compare the vertical motion of the machine when the ECSS switch is turned to ON position and OFF posi- tion. If there is no change in the vertical motion, the accumulator gas pressure has probably dropped. Ask your Komatsu distributor for inspection. 4-40...
Page 333: Method For Checking Function Of Brake Accumulator
Do not to use tires, such as urethane tires, that weigh remarkably more than the standard tires since the machine can be damaged due to an unexpected load. • If a tire not specified by Komatsu is used, rim displacement between the tire and rim may occur. Operator comfort, as well, may be degraded. 4-41...
Page 334 MAINTENANCE PROCEDURE MAINTENANCE Maximum load (kg) Tire size Front tire: 6070 Front tire: 17.5-25-12PR Rear tire: 6070 Rear tire: 17.5-25-12PR Bias Front tire: 6775 Front tire: 20.5-25-12PR Rear tire: 6775 Rear tire: 20.5-25-12PR Front tire: 8000 Front tire: 20.5R25☆ (L3 Rock) Radial Rear tire: 8000 Rear tire: 20.5R25☆...
Page 335: Method For Cleaning And Replacing Fuel Tank Breather Element
MAINTENANCE MAINTENANCE PROCEDURE Appropriate inflation pressure varies depending on the given type of work. For details, see “TIRE PRES- SURE”. METHOD FOR CLEANING AND REPLACING FUEL TANK BREATHER ELEMENT CAUTION If you perform inspection or cleaning while the engine is running, dirt enters the fuel tank and damages the engine.
Page 336: Checks Before Starting
MAINTENANCE PROCEDURE MAINTENANCE After cleaning, install the element to the breather body. At that time, install the element in correct direction. Direct the surface having the mark shown by (6) toward up to install. Install the cover (4). Tighten the nut (3). Tightening torque: 10 to 14 Nm {1.0 to 1.4 kgm} Close the rear grille (1).
Page 337: Every 50 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE • Method for checking electric wiring. • Method for checking fuel level, adding fuel. • Method for checking DEF level and adding DEF. • Method for checking tire pressure. • Method for checking window washer fluid spouting out. •...
Page 338 MAINTENANCE PROCEDURE MAINTENANCE Lower the work equipment horizontally to the ground and stop the engine. By using a grease pump, pump in grease through the grease fitting shown by arrow. Pump in grease until new grease (A) comes out through the gap on either the right or left (or top or bottom) of the lubricated portion.
Page 339: Method For Lubricating Rear Axle Pivot Pin
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR LUBRICATING REAR AXLE PIVOT PIN (2 places) By using a grease pump, pump in grease through the grease fittings shown by arrows. Pump in grease until new grease comes out through the gap on either the right or left (or top or bottom) of the lubri- cated portion.
Page 340 MAINTENANCE PROCEDURE MAINTENANCE NOTICE If the oil is added to above the H mark, stop the engine and wait for the oil to cool down. Then drain the excessive oil through the drain plug (P). It may damage the oil circuit and cause the oil to spurt out.
Page 341: Method For Cleaning Air Conditioner Fresh Air Filter
MAINTENANCE MAINTENANCE PROCEDURE Remove the bolts (1) (4 pieces) and remove the cover (2). Keep pulling the knob (3) and turn the cap of oil filler port (F) counterclockwise to remove. Add oil to the proper level through the oil filler port (F). After adding oil, install the cap and cover (1) of oil filler port (F).
Page 342: Every 250 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE REMARK If the filter is clogged, the air flow will be reduced, and there will be a rumbling sound from the air condition- er unit. Restore the filter (5) and close the cover (3). Insert the starting switch key into the key slot (1) to lock. Do not forget to remove the starting switch key.
Page 343 LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu dis- tributor or a battery manufacturer. Wipe the battery top surface with a wet cloth.
Page 344: Method For Testing Parking Brake
Set the parking brake switch from OFF position (B) to ON position (A). Check that the machine is stopped and held at the current position. If any problem is found, ask your Komatsu distributor for adjustment. METHOD FOR CHECKING LOOSENESS OF WHEEL HUB BOLTS, RETIGHTEN- ING BOLTS Loosening of wheel hub bolt (1) accelerates the wear of the tires and causes accidents.
Page 345: Method For Cleaning Air Conditioner Recirc Air Filter
MAINTENANCE MAINTENANCE PROCEDURE Check the bolt for loosening and tighten it further if neces- sary. Always turn the bolts in the direction of tightening. Tightening torque: 785 to 980 Nm {80 to 100 kgm} If the bolt is broken, replace all of the bolts of the wheel. METHOD FOR CLEANING AIR CONDITIONER RECIRC AIR FILTER WARNING When using conditioner fresh air filter, there is a danger that dirt may scatter and cause personal injury.
Page 346: Every 500 Hours Maintenance
• If the brake oil pressure caution lamp lights up when the brake pedal is depressed 5 times or less, the gas pressure in the accumulator may be low. Ask your Komatsu distributor for inspection. REMARK The inspection must be done within 5 minutes after the engine stops. If the engine is kept stopped, the gas pressure in the accumulator lowers and the inspection cannot be made.
Page 347 Loosen the drain plug (P) and drain the oil. Check the drained oil. If it contains much metallic powder or foreign material, contact your Komatsu distributor. Tighten the drain plug (P). Open the engine side cover (2) on the left side of the ma- chine.
Page 348: Method For Replacing Fuel Prefilter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 349 MAINTENANCE MAINTENANCE PROCEDURE Turn the filter cartridge (4) counterclockwise by using the filter wrench, and remove it. Install the currently removed transparent cup (3) to the bottom of the new fuel prefilter cartridge. At this time, be sure to replace the O-ring (7) with a new one. NOTICE When installing the transparent cup, thinly apply oil to the packing surface, contact it to the sealing surface of filter cartridge (4), and then tighten it 1/4 to 1/2 turn.
Page 350: Every 1000 Hours Maintenance
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 351 MAINTENANCE MAINTENANCE PROCEDURE Open the engine side cover (1) on the right side of the ma- chine. Place a container under the filter cartridge to catch the fuel. Turn filter cartridge (2) counterclockwise by using the filter wrench, and remove it. Clean the filter head.
Page 352: Method For Cleaning Transfer Case Breather
MAINTENANCE PROCEDURE MAINTENANCE Fill up the fuel tank with fuel (to the level where the float is at the highest position). Loosen the knob of feed pump (4), pull it out, then pump it in and out until the movement becomes heavy.
Page 353 MAINTENANCE MAINTENANCE PROCEDURE After removing dirt and dusts around the breather (5), re- move the breather (5) and immerse it in detergent liquid to clean. While the breather is removed, use care to prevent entry of dusts through the mounting location of the breather. METHOD FOR CHANGING OIL IN TRANSFER CASE AND CLEANING TRANSFER CASE STRAINER WARNING...
Page 354: Method For Replacing Hst Oil Filter Cartridge
MAINTENANCE PROCEDURE MAINTENANCE Add the refill capacity of oil through the oil filler port (F). 10. After adding the oil, check that the oil level is proper by re- ferring to “METHOD FOR CHECKING OIL LEVEL IN TRANSFER CASE AND ADDING OIL”. NOTICE •...
Page 355 MAINTENANCE MAINTENANCE PROCEDURE Check the hydraulic oil level. If the oil level is between H and L of sight gauge (G), it is proper. If the oil level is below the L mark, add oil according to the following procedure. Remove the bolts (2) (4 pieces) and remove the cover (3).
Page 356: Every 2000 Hours Maintenance
After greasing, wipe off any old grease that is pushed out. METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. METHOD FOR CHECKING AND REPLACING ALTERNATOR BELT •...
Page 357 MAINTENANCE MAINTENANCE PROCEDURE Remove the bolts (1) (4 pieces) and remove the cover (2). Keep pulling the knob (3) and turn the cap of oil filler port (F) counterclockwise to remove. Place a container to catch the drained oil under the drain plug (P).
Page 358: Method For Replacing Hydraulic Oil Filter Cartridge
MAINTENANCE PROCEDURE MAINTENANCE NOTICE If the engine is run at high speed immediately after the startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause damage to the piston packing, etc. 10. Extend and retract each of the steering, bucket, and boom cylinders to the stroke end 3 to 4 times. 11.
Page 359 MAINTENANCE MAINTENANCE PROCEDURE Remove the bolts (4) (2 pieces) and remove the cover (5). Place a container to catch the drained oil under the filter cartridge (6). Turn the filter cartridge (6) counterclockwise by using the filter wrench, and remove it. Clean the filter head.
Page 360: Method For Replacing Hydraulic Tank Breather Element
MAINTENANCE PROCEDURE MAINTENANCE Keep pulling the knob (3) and turn the cap of oil filler port (F) counterclockwise to remove. Add oil to the proper level through the oil filler port (F). After adding oil, install the cap of the oil filler port (F). 13.
Page 361: Method For Replacing Hst Drain Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING HST DRAIN FILTER CARTRIDGE WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 362 MAINTENANCE PROCEDURE MAINTENANCE If the oil level is below the L mark, add oil according to the following procedure. Remove the bolts (4) (4 pieces) and remove the cover (5). Keep pulling the knob (6) and turn the cap of oil filler port (F) counterclockwise to remove.
Page 363: Method For Changing Oil In Axle Case
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHANGING OIL IN AXLE CASE WARNING • When changing the oil, apply the parking brake and secure the front and rear frames with the frame lock bar. • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 364: Method For Replacing Air Conditioner Recirc Air Filter
MAINTENANCE PROCEDURE MAINTENANCE Wipe off oil of dipstick (G) installed to plug (1) by using a piece of cloth. Set dipstick (G) as shown in the figure. (2): Axle (3): Spot facing surface Check the oil level. The oil level is appropriate if it is between 2 grooves (H) and (L) of the dipstick.
Page 365: Method For Cleaning Brake Circuit Strainer
MAINTENANCE MAINTENANCE PROCEDURE Insert the starting switch key into the key slot (1) to unlock. Loosen the knob (2) and open the cover (3). Loosen the knob (4) and take out the filter (5). Install the new filter (5), and tighten the knob (4). Close the cover (3) and tighten the knob (2).
Page 366: Method For Checking Brake Disc Wear Amount
MAINTENANCE PROCEDURE MAINTENANCE Take out the strainer (7) and wash it in the clean diesel fuel. Install the strainer (7) into strainer case (8) with the protru- sion (O-ring) side toward you, and install it with flange (6). Install the elbow (5). Install the cover (4) with bolts (3) (2 pieces).
Page 367: Method For Checking Function Of Ppc Accumulator
Ask your Komatsu distributor to have the alternator checked. If the engine is started frequently, have this inspection performed every 1000 hours. METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. 4-75...
Page 368: Method For Replacing Kccv Filter Element
NOTICE • Komatsu recommends using Komatsu genuine parts for replacement parts. • If the engine is operated without the filter element, the turbocharger and aftercooler become dirty and their performance will lower and it can cause engine problems such as overrun caused by suc- tion of oil.
Page 369 MAINTENANCE MAINTENANCE PROCEDURE After the ring (3) comes off, remove the case (4) from body (2), and remove the element (5). There may be oil accumulated or sticking in the case and element. Take care not to spill the oil when replacing the element.
Page 370: Method For Replacing Def Filter
Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without the DEF filter attached, or with the filter other than Komatsu gen- uine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine.
Page 371 MAINTENANCE MAINTENANCE PROCEDURE After the engine is stopped, the DEF system devices automatically purge the DEF in the DEF injector and DEF pump and return it to the DEF tank to prevent malfunction of the devices caused by freezing of the DEF or dep- osition of urea.
Page 372 MAINTENANCE PROCEDURE MAINTENANCE Remove the filter cap (6) at the lower part of DEF pump and remove the element (7). Turn the cap (9) of filter removal tool (8) and remove it. Check the installation of spacer (10). Insert the filter removal tool (8) into the lower part of the DEF pump and thrust in by hand.
Page 373: Method For Replacing Def Tank Breather Element
MAINTENANCE MAINTENANCE PROCEDURE Slide the filter (11) down, and remove the spacer (10) from the filter removal tool (8). 10. Pull the filter (11) up while pushing in the tip of filter remov- al tool (8), and remove it. 11. Return the removed spacer (10) to the filter removal tool (8), and keep them.
Page 374 If the machine is operated without the DEF tank breather element attached, or with the element oth- er than Komatsu genuine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine. Never operate the machine without the DEF tank breather element attached, nor use the element other than Komatsu genuine parts.
Page 375: Every 4000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Remove the nut (7) of breather assembly (6) at the top of the DEF tank, then remove the cover (8). Replace the breather element (9) with a new one. When installing the breather element (9), be sure to set the TOP mark (10) side facing upward.
Page 376: Method For Lubricating Drive Shaft
HST circuit hose mission system Work equipment hydraulic Main pump delivery hose system Main pump delivery hose other than described Ask your Komatsu distributor above for replacement. Hydraulic drive fan hose (Exhaust fan) External work equipment hose Lift cylinder hose •...
Page 377: Method For Checking Water Pump
After greasing, wipe off any old grease that is pushed out. METHOD FOR CHECKING WATER PUMP Check for leakage of water and oil around the water pump. If any problem is found, ask your Komatsu distributor to perform disassembly, repair, or replacement.
Page 378: Every 4500 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE If there are any problems, the related parts must be replaced. Ask your Komatsu distributor for replacement. METHOD FOR CHECKING WEAR OF DAMPER GEAR Checking is not necessary for initial 4000 hours. Ask your Komatsu distributor for checking the wear amount of damper gear.
Page 379: Specifications
SPECIFICATIONS...
Page 380: Specifications: Wa200-8
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS: WA200-8 Item Unit WA200-8 Operating weight kg 11785 (with bolt on cutting edge (BOC)) Normal load kg 3200 Bucket capacity Heaped m Engine model Komatsu SAA4D107E-3 SAE J1995 95.2 {128} / 2000 {2000} (gross) kW { HP} /...
Page 381 SPECIFICATIONS SPECIFICATIONS *2: Value when equipped with the pin-on 2.0 m bucket. 9 J W 0 1 4 5 6...
Page 383: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 384: Bucket And Tire Selection
20.5-25-12PR (L3: Rock) 20.5R25☆ (L3: Rock) BOC: Abbreviation for Bolt On Cutting edge You need to change the travel speed display on the machine monitor according to the tire size. When installing the optional tires, ask your Komatsu distributor for installation.
Page 385: Handle Hydraulic Type Quick Coupler
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC TYPE QUICK COUPLER HANDLE HYDRAULIC TYPE QUICK COUPLER WARNING Before operating the machine, check that the attachment is correctly connected. If it is not correctly in- stalled, the attachment may fall off and cause serious injury. •...
Page 386: Method For Removing Attachment
HANDLE HYDRAULIC TYPE QUICK COUPLER ATTACHMENTS AND OPTIONS QUICK COUPLER LOCK RELEASE PILOT LAMP Quick coupler lock release pilot lamp lights up when the quick coupler attachment switch is in the position of decoupling. In order to release the quick coupler, operate the multifunction mono-lever to TILT side while the quick coupler attachment switch is in the decoupling position.
Page 387: Method For Installing Attachment
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC TYPE QUICK COUPLER Check that the lock pins have been removed. The lock pin indicators (3) may not be visible. g0038103 Lower the attachment completely to the ground and set it in a stable position. g0038104 Tilt the coupler forward slowly and lower it slowly so that it separates from the attachment hook.
Page 388 HANDLE HYDRAULIC TYPE QUICK COUPLER ATTACHMENTS AND OPTIONS Pull lock (A) of the quick coupler switch in the direction of the arrow (b), and push in to RELEASE position (a). • Keep the quick coupler attachment switch pressed un- til the work of the step 8 is completed. •...
Page 389 ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC TYPE QUICK COUPLER Raise the coupler slowly as the machine travels forward, keep raising it until coupler tube comes to be connected with the attachment hook and the attachment is a little lift- ed off from the ground. Check that the attachment is horizontal to the left and right and that each hook is correctly inserted.
Page 390: Handle Fork
HANDLE FORK ATTACHMENTS AND OPTIONS HANDLE FORK EXPLANATION OF COMPONENTS ON MACHINES WITH FORK (1) Multifunction mono-lever (2) Attachment selector switch MULTIFUNCTION MONO-LEVER The multifunction mono-lever is used to operate the boom and fork. NOTICE Do not use “FLOAT” position when lowering the fork.
Page 391: Machine Operations And Controls
ATTACHMENTS AND OPTIONS HANDLE FORK Position (a): RAISE When the multifunction mono-lever is pulled further from the “RAISE” position, the lever stops in that position. The boom stops at the preset position and the lever returns to “HOLD” position at the same time when the remote boom posi- tioner is enabled.
Page 392 HANDLE FORK ATTACHMENTS AND OPTIONS METHOD FOR ADJUSTING FORK POSITIONER Lower the fork to the ground, and make it horizontal. Return the multifunction mono-lever to “HOLD” position. Press the work equipment lock switch and lock the work equipment (the pilot lamp lights up). Stop the engine.
Page 393 ATTACHMENTS AND OPTIONS HANDLE FORK Loosen the nut (1), and adjust the position of proximity switch (3) so that the rear end (A) of the bar (2) is matched to the center of sensory surface (B) of the proximity switch (3).
Page 394 HANDLE FORK ATTACHMENTS AND OPTIONS Adjust the space between the forks according to the size of the load. Secure an enough space as possible for the fork so that the load will be stable. Set the forks horizontal, drive the machine forward slowly, and insert the forks under the load so that the load can be loaded on the center of the forks.
Page 395 ATTACHMENTS AND OPTIONS HANDLE FORK • Keep the load at the height near the ground usually when carrying the load. Perform the steering operation with care if it is unavoidable to lift the load high. • Use the 1st or 2nd in the speed range when carrying the load.
Page 396: Pcs(Proportional Control Switch)
PCS(PROPORTIONAL CONTROL SWITCH) ATTACHMENTS AND OPTIONS PCS(PROPORTIONAL CONTROL SWITCH) PCS (Proportional Control Switch) is used to operate the third attachment. The amount of the hydraulic oil discharged by the switch opera- tion is in proportion to the stroke of the switch. The switch has 2 control modes;...
Page 397 ATTACHMENTS AND OPTIONS PCS(PROPORTIONAL CONTROL SWITCH) OIL FLOW CONTROL MODE PILOT LAMP (FIXED OIL FLOW MODE) Oil flow control mode pilot lamp (fixed oil flow mode) lights up when the flow control mode of PCS is in the fixed oil flow mode.
Page 398: Method For Setting Pcs
PCS(PROPORTIONAL CONTROL SWITCH) ATTACHMENTS AND OPTIONS ATTACHMENT OIL FLOW LEVEL The attachment oil flow level indicates the maximum flow level which has been set. It indicates the level 0 to 8 according to the attachment flow rate level which has been set. It is displayed in green (A) in the normal state, and in orange (B) under the detent control.
Page 399 ATTACHMENTS AND OPTIONS PCS(PROPORTIONAL CONTROL SWITCH) To change the setting name, select “Attachment Name Setting” and press ENTER switch (2). Change the alphabet at the cursor with UP or DOWN switches and move the cursor with menu switch (1). After completing the change, validate it with ENTER switch (2).
Page 400: Auto-Greasing
The settings when shipping from the factory are as follows. Lubrication interval: Every 1 hour Lubrication time: 9 minutes When changing the settings of the lubrication cycle for the heavy-duty operations, consult your Komatsu distrib- utor. Method for operating the auto-greasing system The pump with grease tank is located at the position as shown in the figure.
Page 401 ATTACHMENTS AND OPTIONS AUTO-GREASING LED display (1) Three-digit LED display: Values and operating state (2) Pause time (3) Pump operation (4) Monitoring of system function by means of an external cycle switch (5) Without function (6) Fault message Push button switch (1) Turn on display Display values and parameters Set values and parameters...
Page 402 AUTO-GREASING ATTACHMENTS AND OPTIONS Display Denotation Explanation Control function c = COUNTER Attention! Not used CO = CONTACT This mode causes a malfunction. C = Cycle Display of beginning of menu O = OFF “Monitoring settings” P = Pressure Monitoring The monitoring functions PS and No system monitoring CS are deactivated.
Page 403: Initial 10 Hours Maintenance (Only For The First 100 Hours)
The sequence of opera- tions is stopped. If the fault message will appear again after the reset, consult your Komatsu distributor. INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) For the first 100 hours of operation on a new machine, press the switch shown in the figure every 10 hours to actuate the manual greasing.
Page 404 Komatsu distributor. Maintenance work should be performed if needed or every 50 hours. If any problem occurs, consult your Komatsu distributor. Prepare the grease. For the types of grease, see “METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
Page 405: Replacement Parts
REPLACEMENT PARTS...
Page 406: Periodic Replacement Of Defined Life Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. DEFINED LIFE PARTS LIST Periodical replacement parts...
Page 407: Consumable Parts
The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
Page 408: Recommended Fuel, Coolant, And Lubricant
Komatsu genuine oils are conditioned to maintain the reliability and durability of Komatsu construction equipment and components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recom- mend any commercially available lubricant additive. •...
Page 409 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT The symbols used in the lubrication chart are explained as follows. Symbol Meaning of the symbol Symbol Meaning of the symbol Read the Operation and Maintenance Supply grease Manual. Change the engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level...
Page 410: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
EN 590 Class 2 Fuel tank Diesel fuel EN 590 Grade D DEF tank DEF (Note.6) Air conditioner Refrigerant R134a (HFC134A) KES: Komatsu Engineering Standard Specified capacity Refill capacity Reservoir Liter Liter Engine oil pan 15.5 Transfer case Hydraulic System Axle (Front) 18.5...
Page 411: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems in the cooling system, including the engine.
Page 413 INDEX INDEX Symbols Always use clean washer fluid........ 4-2 Appoint leader when working with others..... 2-31 12/24 display mode..........3-76 Armrest angle - Adjust........3-148 2-stage low idle switch.......... 3-92 Armrest height and angle - Adjust.......3-155 2-stage low idling pilot lamp........3-32 Ashtray..............3-106 Attachment - Install..........
Page 414 INDEX DEF hose - Replace..........4-86 DEF level - Check..........3-178 Cab door - Open / Close........3-101 DEF level caution lamp......... 3-22 Cab door handle..........3-102 DEF level gauge........... 3-40 Calendar setting............3-73 DEF low level guidance........3-35 Cap and cover with lock........3-105 DEF system caution lamp........
Page 415 INDEX Engine - Check starting condition and unusual noise.. Filter................ 4-8 ..............3-162 Fin - Clean by rotating cooling fan in reverse..4-29 Engine - Operate / Check after starting....3-162 Fin - Clean with compressed air......4-29 Engine - Operate / Check before starting... 3-156 Fins - Open engine side cover / Clean....4-31 Engine - Start..........3-158,3-222 Fins - Open rear grille / Clean.......4-30...
Page 416 Keep machine clean..........2-13 Machine monitor - Operate when operator identifica- KMAX tooth - Replace.......... 4-34 tion function is available without skip.....3-80 Komatsu Closed Crankcase Ventilation (KCCV).3-114 Machine monitor - Operate when starting engine in Komatsu genuine lubricants........4-2 abnormal situation......... 3-14 Komatsu genuine replacement parts......
Page 417 PCS - Set.............. 6-16 Maintenance interval when diesel fuel mixed with bio- PCS (Proportional Control Switch)....3-94,6-14 fuel is used.............4-13 Perform KOWA (Komatsu Oil Wear Analysis)..4-7 Maintenance of air conditioner......2-38 Periodic replacement of defined life parts.....2-39 Maintenance procedure........4-15 Permissible water depth........3-177...
Page 418 Slow-blow fuse - Replace........4-39 R.H. meter display - Select........3-71 Specifications............5-2 Radiator coolant level caution lamp...... 3-26 Specifications - WA200-8........5-2 Radiator fan automatic reverse mode....3-58 Speed range - Select.......... 3-169 Radiator fan manual reverse mode.......3-57 Speed range selector switch.........3-97 Radiator fin and cooler fin - Clean......
Page 419 INDEX Steering cylinder pin - Lubricate......4-50 Steering low oil pressure caution lamp....3-34 Unauthorized modification........2-19 Steering oil pressure caution lamp......3-23 Understanding the machine........2-13 Steering system caution lamp.......3-23 Unlock knob for slide window of cab....3-103 Steering tilt lock lever..........3-100 Up switch..............

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