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Komatsu WA600-8 Operation & Maintenance Manual

Komatsu WA600-8 Operation & Maintenance Manual

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Operation &

Maintenance Manual

WA600

WHEEL LOADER

SERIAL NUMBER

WA600-8

WARNING

Unsafe use of this machine may cause serious injury or

death. Operators and maintenance personnel must read

this manual before operating or maintaining this

machine. This manual should be kept inside the cab for

reference and periodically reviewed by all personnel who

will come into contact with the machine.

- 80001

and up

-8

ORIGINAL INSTRUCTIONS

EENAM03470

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Page 1 Operation & EENAM03470 Maintenance Manual WA600 WHEEL LOADER SERIAL NUMBER WA600-8 - 80001 and up WARNING ORIGINAL INSTRUCTIONS Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
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 Keep it in pocket (1) behind 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: Safety Information
FOREWORD SAFETY INFORMATION 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 6: Noise
NOISE FOREWORD NOISE Two labels indicating the machine noise level are affixed on the machine. • 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 2.5dB, in accordance with ISO 11201...
Page 7: Vibration Levels
FOREWORD VIBRATION LEVELS VIBRATION LEVELS When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper- ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.
Page 8 VIBRATION LEVELS FOREWORD • Do not repeatedly handle and lift loads...
Page 9: Introduction
FOREWORD INTRODUCTION 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 (3-223)”.
Page 10 INTRODUCTION FOREWORD 12 m radius visibility The figure below shows a visibility from the machine for a radius of 12 m. Shaded area (B) in the figure shows an area whose view is blocked when the machine is equipped with the mirrors, rearview camera, and other visibility assistant devices. Be fully aware that there is an area where the operator cannot see when operating the machine.
Page 11: Engine Technology To Conform Exhaust Gas Emission
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union. • Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process to burn the soot is performed automatically to keep the filtering performance of KDPF high.
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: Service Meter Location
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: KOMATSU LTD. Address: 2-3-6 Akasaka Minato-ku, Tokyo 107-8414 Japan Authorised representative: KOMATSU EUROPE INT. Address: Mechelsesteenweg 586 B-1800 Vilvoorde Belgium Distributor name Address Service personnel Phone/Fax 1-11...
Page 14: Serial Plate
SERIAL PLATE FOREWORD SERIAL PLATE EI000001 MACHINE DESIGNATION/TYPE ENGINE POWER SERIAL NUMBER PRODUCT IDENTIFICATION NUMBER YEAR OF CONSTRUCTION MANUFACTURER OPERATING MASS AUTHORISED REPRESENTATIVE 1-12...
Page 15: Declaration Of Conformity
FOREWORD DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY The manufacturer/Authorised representative The manufacturer Authorised representative KOMATSU LTD. KOMATSU EUROPE INT. 2-3-6 Akasaka Mechelsesteenweg 586 Minato-ku, Tokyo 107-8414 B-1800 Vilvoorde Japan Belgium Declares that this machine: WA600-8 Fulfils all the relevant provisions of following EC Directives:...
Page 16: Table Of Contents
TABLE OF CONTENTS FOREWORD TABLE OF CONTENTS FOREWORD..............................1-1 BEFORE READING THIS MANUAL ......................1-2 SAFETY INFORMATION .......................... 1-3 NOISE............................... 1-4 VIBRATION LEVELS ..........................1-5 VIBRATION - OPERATING CONDITION ................... 1-5 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............1-5 INTRODUCTION ............................
Page 17 OTHER TROUBLE......................... 3-291 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 18 EVERY 8000 HOURS MAINTENANCE ................... 4-89 EVERY 9000 HOURS MAINTENANCE ................... 4-90 SPECIFICATIONS ............................5-1 SPECIFICATIONS ............................ 5-2 SPECIFICATIONS: WA600-8......................5-2 ATTACHMENTS AND OPTIONS ........................6-1 BUCKET AND TIRE SELECTION......................6-2 HANDLE STEERING WHEEL SPEC MACHINE..................6-3 GENERAL VIEW..........................6-3 EXPLANATION OF COMPONENTS ....................
Page 19 TABLE OF CONTENTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-5 LUBRICATION CHART ........................7-5 METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-7 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-9 INDEX................................8-1 1-17...
Page 21: 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 22 SAFETY SAFETY SAFETY SAFETY LABELS ............................2-4 LOCATION OF SAFETY LABELS......................2-5 CONTENTS OF SAFETY LABELS ......................2-7 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........... 2-15 PRECAUTIONS BEFORE STARTING OPERATION................2-15 ENSURE SAFE OPERATION ......................2-15 UNDERSTAND THE MACHINE ....................... 2-15 PREPARATIONS FOR SAFE OPERATION ....................
Page 23 SAFETY SAFETY PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES........2-33 PRECAUTIONS WHEN PARKING MACHINE ................. 2-33 PRECAUTIONS FOR TRANSPORTATION..................... 2-34 PRECAUTIONS WHEN LOADING AND UNLOADING ..............2-35 TOWING AND BEING TOWED....................... 2-35 PRECAUTIONS FOR TOWING AND BEING TOWED..............2-35 PRECAUTIONS FOR MAINTENANCE ......................
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: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS...
Page 26 SAFETY LABELS SAFETY (*) Only for the machine equipped with ECSS 1. Caution before operating 3. Caution when traveling in reverse 2. Caution when leaving operator's seat 4. Caution for electric cables...
Page 27: Contents Of Safety Labels
SAFETY SAFETY LABELS 5. Prohibition of trespassing 16. Caution for hot EGR pipe 6. Caution for frame lock bar 17. Caution for high-pressure common rail 7. Caution for high-temperature coolant 18. Alternate exit of cab 8. Caution for high-temperature oil 19.
Page 28 SAFETY LABELS SAFETY (3) Caution when traveling in reverse “09802–D0880” • Sign indicates a hazard of rear working and advancing be- hind. • Read manual before operation. WARNING To prevent SEVERE INJURY or DEATH, do the following before moving machine or its attachments : •...
Page 29 SAFETY SAFETY LABELS (5) Prohibition of trespassing “09162-C0641” • Sign indicates a crush hazard between the articulating parts of vehicle. • Keep away from the vehicle when it is moving. (6) Caution for frame lock bar “09161-C0641” • Sign indicates a crush hazard between the articulating parts of vehicle.
Page 30 SAFETY LABELS SAFETY (8) Caution for high-temperature oil “09653–A0641” • Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot. • Allow radiator or hydraulic tank to cool before removing cap.
Page 31 If some modification is applied to the ROPS or FOPS, it may effect the strength and may not comply with the stand- ard. Consult Komatsu Distributor before altering. • ROPS or FOPS may provide less protection if it has been structurally damaged or involved roll-over. Con- sult Komatsu Distributor in that case.
Page 32 SAFETY LABELS SAFETY (15) Prohibition of start by short-circuiting “09842- A0481” • Start the engine only after sitting down in the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury of fire.
Page 33 SAFETY SAFETY LABELS (18) Alternate exit “426-93-51110” (19) Caution for blast site (Machine with KOMTRAX Plus) “09845–00480” • Sign indicates an explosion hazard caused by active radio transmitter at a blast zone. • Keep machine at a safe distance from a blast zone and detonator.
Page 34 SAFETY LABELS SAFETY (22) Prohibition of getting on or off hood “09805-C0641” • Sing indicates a hazard of falling. • Do not stand on this place here. (23) Caution when removing fan net “09667-A088B” • Sign indicates a hazard of rotating parts, such as belt. •...
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: Precautions To Prevent Fire
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: Prevent Fire
Fire around the machine due to highly heated exhaust gas This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF). 2-17...
Page 38: Precautions When Getting On Or Off Machine
When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to the regener- ation disable to prevent fire hazards due to highly heated exhaust gas during the aftertreatment devices regen- eration. For setting, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-143)”. Explosion caused by lighting equipment •...
Page 39: No Jumping On Or Off Machine
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • Do not get on or off the machine with tools in your hand. NO JUMPING ON OR OFF MACHINE Getting on or off the moving machine can cause serious personal injury or death. Always observe the following. •...
Page 40: Precautions When Standing Up From Operator's Seat
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT When standing up from the operator's seat to adjust the opera- tor's seat, be sure to lower the work equipment to the ground, and lock the work equipment by pressing the work equipment lock switch (1) (the pilot lamp lights up).
Page 41: Alternate Exit Of Cab
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE Whenever leaving the machine, be sure to lower the work equipment to the ground, lock the work equipment by pressing the work equipment lock switch (1) (the pilot lamp lights up). Set the steering lock lever (2) to LOCK position (L), and park- ing brake switch (3) to ON (operate) position (A), and stop the engine.
Page 42: Do Not Get Caught
• 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 43: Precautions Related To Attachments And Options
• Any personal injuries, product failures, physical loss or damage, or influence on the environment resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu. • When installing optional parts or attachments, contact your Komatsu distributor for advice to any potential problems or safety and legal requirements.
Page 44: 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 45: Ensure Good Visibility
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 46: 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 47: Precautions When Starting Engine
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 48: 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 49: Precautions When Traveling In Forward Or Reverse
SAFETY PRECAUTIONS FOR OPERATION • Fasten the seatbelt. When the brakes are applied sudden- ly, the operator may be thrown out of the operator's seat. It is dangerous and may cause personal injury. • Check the operating condition of the machine, work equip- ment, and travel and brake systems.
Page 50: Precautions When Traveling On Slopes
PRECAUTIONS FOR OPERATION SAFETY • When driving the machine on a level ground, keep the work equipment at height (A) of 50 to 60 cm above the ground. If that height is not maintained between the work equipment and the ground, the work equipment may get stuck in the ground and the machine may tip over.
Page 51: Method Of Using Brakes
SAFETY PRECAUTIONS FOR OPERATION • Keep the work equipment at height (A) of approximately 20 to 30 cm above the ground. In case of emergency, lower the work equipment to the ground immediately to help stopping the machine. • Always drive the machine straight up or down a slope. Driving the machine at an angle or across the slope is ex- tremely dangerous.
Page 52: Precautions When Operating Machine
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN OPERATING MACHINE • When using the machine, to prevent serious personal injury or death caused by the work equipment or by the machine tipping over due to overloading, do not use the machine beyond the permitted performance of the machine such as the maximum permitted load for the structure of the machine.
Page 53: Precautions When Operating On Snow Or Frozen Surfaces
SAFETY PRECAUTIONS FOR OPERATION • 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 54: 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 55: Towing And Being Towed
SAFETY PRECAUTIONS FOR OPERATION • For details of the transportation procedure, see “TRANSPORTATION (3-275)”. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is improper when loading or unloading the machine, it is dangerous that the machine may tip over or fall. It requires particular attention. Always observe the following. •...
Page 56: Precautions For Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY 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 57: Guards
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 58: Two Workers For Maintenance When Engine Is Running
• If the automatic active regeneration of KDPF starts during maintenance work, surroundings of KDPF become high temperature. When performing maintenance work, perform the after- treatment devices regeneration disable according to “HAN- DLE Komatsu Diesel Particulate Filter (KDPF) (3-143)”. 2-38...
Page 59: Turn Off Ecss Switch Before Performing Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE • Lower the work equipment to the ground and press work equipment lock switch (1) to lock the work equipment (the pilot lamp lights up) and prevent it from moving. • Set the steering lock lever (2) to LOCK position (L). •...
Page 60: Precautions For Check And Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS WHEN WORKING ON MACHINE • When performing maintenance work on the machine, maintain the foothold clean and orderly to prevent falling. Always observe the followings. • Avoid spilling of oil and grease. • Do not litter the tools. •...
Page 61: Precautions For Welding
SAFETY PRECAUTIONS FOR MAINTENANCE • When performing electric welding • When handling the battery • When replacing the fuse, etc. PRECAUTIONS FOR WELDING Welding operations must always be performed by a qualified welder and in a place equipped with proper equip- ment.
Page 62: Precautions When Using Hammer
PRECAUTIONS FOR MAINTENANCE SAFETY • Tighten the battery cable terminals securely. • Secure the battery firmly in the specified position. PRECAUTIONS WHEN USING HAMMER When using a hammer, pins may come out or metal particles may be scattered. It is dangerous and may cause serious personal injury or death.
Page 63: Precautions For High-Pressure Fuel
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 64: Handle Accumulator And Gas Spring
• 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 65: 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 66: Precautions For Storing Tires
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR STORING TIRES Tires for construction equipment are extremely heavy, it may lead to serious personal injury or death. To maintain safety, al- ways observe the following. • As a basic rule, store the tires in a warehouse which unau- thorized persons cannot enter.
Page 67: 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 69: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 70: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Bucket (11) Rear wheel (2) Front wheel (12) Side working lamp (if equipped) (3) Bell crank (13) Steering cylinder (4) Bucket cylinder (14) Lift cylinder (5) Turn signal lamp (15) Front lower working lamp (if equipped) (6) Headlamp (16) Boom (7) Front working lamp...
Page 71: Controls And Gauges Names
OPERATION GENERAL VIEW CONTROLS AND GAUGES NAMES...
Page 72 GENERAL VIEW OPERATION (1) AJSS lever (23) Room lamp switch (2) Directional selector switch (24) Room lamp 2 switch (3) Steering lock lever (25) Staircase lighting switch (4) Horn switch (26) Revolving lamp switch (if equipped) (5) Downshift switch (27) Working lamp switch (6) Upshift switch (28) Rear heated wire glass switch (7) Engine shutdown secondary switch...
Page 73 OPERATION GENERAL VIEW MACHINE MONITOR EQUIPMENT NAME General view (a) LCD unit (c) Meter unit (b) LED unit (1) Torque converter oil temperature gauge (17) Hydraulic oil temperature caution lamp (2) Torque converter oil temperature caution lamp (18) Hydraulic oil temperature gauge (3) Engine coolant temperature caution lamp (19) Fuel level caution lamp (4) Engine coolant temperature gauge...
Page 74 GENERAL VIEW OPERATION Display of liquid crystal unit (A) Standard screen (B) ECO guidance screen (30) Message display (39) Torque converter lockup pilot lamp (31) Auto-digging pilot lamp (40) Shift hold pilot lamp (32) AJSS pilot lamp (for the machine equipped with (41) Preheating pilot lamp AJSS) (42) Fan reverse pilot lamp...
Page 75 OPERATION GENERAL VIEW (C) Maintenance time warning screen (E) User menu screen (D) Warning screen (47) Maintenance time caution lamp (50) Warning display (48) Guidance icon (51) Action level display (49) Seat belt caution lamp...
Page 76: Other Equipment Name
GENERAL VIEW OPERATION OTHER EQUIPMENT NAME Inside of cab (1) Rearview monitor (7) Lunch box tray (2) Ashtray (8) Fuse (3) 24 V power supply (9) Cool box (3) Cigarette lighter (10) Cup holder (4) 12 V power supply (11) Unlock knob for cab window (5) AUX (12) Cab door inner lock (6) Open knob for alternate exit of cab...
Page 77 OPERATION GENERAL VIEW Left side of the machine (14) Front wiper (22) Circuit breaker (15) Knob for cab door (23) Battery disconnect switch (16) Frame lock bar (24) System operating lamp (17) Rearview camera (25) Auxiliary engine starting connector (18) Towing pin (26) L.H.
Page 78 (36) DEF filter (30) Fire extinguisher (if equipped) (37) Dust indicator (31) Rear fender (if equipped) (38) R.H. DEF injector (32) Komatsu Closed Crankcase Ventilation (hereafter (39) R.H. SCR assembly KCCV) ventilator (40) R.H. KDPF (33) DEF tank (34) DEF pump...
Page 79: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS 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 80 NOTICE If the pilot lamp, caution lamp, 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 At starting of the engine, battery voltage may drop abruptly depending on the ambient temperature or battery condition, and the machine monitor may go out temporarily or restart, but it is not a trouble.
Page 81 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 82 (3), and the screen changes to the Check Be- fore Starting screen BB without inputting ID number. REMARK • Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identifica- tion function. •...
Page 83 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 84 EXPLANATION OF COMPONENTS OPERATION If there is maintenance time warning when starting the engine When the machine monitor is started, if the time to the next maintenance of any item is 30 hours or less, starting screen AA is displayed for 2 seconds and then it is changed to maintenance time warning screen GG. When the menu switch displayed in guidance icon (2) is press- ed, “Maintenance”...
Page 85 OPERATION EXPLANATION OF COMPONENTS If any trouble occurs during operation, the standard screen BB changes to the failure display screen FF. When ENTER switch is pressed while the guidance icon is dis- played, “Current Abnormality” screen is displayed. For “Current Abnormality” screen and the remedies, see “OC- CURRED FAILURE CODE DISPLAY (3-19)”.
Page 86 Stop the operation and move the machine to a safe Sounds in- Lights up Lights up place, and then ask your Komatsu distributor for in- termittently in red spection and maintenance. High If there is an overrun related display, reduce the en- gine speed and machine travel speed while continu- ↑...
Page 87 OPERATION EXPLANATION OF COMPONENTS REMARK • When the action level is “L01”, the “L01” is displayed only for 2 seconds after a failure occurs, and then it disappears. • If plural failures occur at the same time, the action level with the highest urgency (the greatest number) is dis- played.
Page 88 OPERATION (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 actions according to the displayed message. (F) Contact telephone number The telephone number of your Komatsu distributor is displayed.
Page 89 OPERATION EXPLANATION OF COMPONENTS DOWN switch Move to the next page. When on the last page, it moves to the first page. RETURN switch Return to the standard screen. ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about over- heating of the engine coolant.
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. 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 91 After a while the preceding remedies have been taken, the oil temperature decreases and the caution lamp goes out. If the brake oil temperature caution lamp frequently lights up, record the operation, travel speed, and the state of braking just before the lamp lights up, then consult your Komatsu distributor. 3-23...
Page 92 If the caution lamp lights up in yellow and action level “L01” is displayed, always perform inspection and maintenance after the operation is finished. Ask your Komatsu distributor for the inspection and mainte- nance as needed. 3-24...
Page 93 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. SYSTEM CAUTION LAMP The system caution lamp warns about abnormality in the ma- chine system, including the sensors.
Page 94 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 95 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 96 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 97 ING OIL (3-173)”. If the oil level drops again in a short time, the engine oil may be leaking. Ask your Komatsu distributor for inspection and repair. ENGINE OVERRUN CAUTION LAMP The engine overrun caution lamp warns the operator that the engine speed is higher than the allowable range.
Page 98 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. FAN-REVERSE OPERATION CAUTION LAMP The wrong operation in fan reverse mode caution lamp warns about misoperation while the fan is rotating in reverse.
Page 99 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. SUBTRACTION TARGET OVER CAUTION LAMP (if equipped)
Page 100 EXPLANATION OF COMPONENTS OPERATION REMARK When depressing the L.H. brake pedal or decreasing the driving force with the driving force control dial, the modulation clutch slips, and the temperature will increase due to the friction. Especially, if the driving force is decreased with the driving force control dial, and if the digging work is per- formed at 1st speed, perform the work from starting pushing-in to finishing scooping within 10 seconds in order to prevent the modulation clutch from overheating.
Page 101 OPERATION EXPLANATION OF COMPONENTS Machine conditions under which centralized warn- Other caution lamps ing lamp lights up When directional lever or directional selector switch is not in NEUTRAL position (N) while the parking brake is applied When the gear is shifted down or the travel direc- tion is changed while the travel speed is high PILOT DISPLAY AND METER DISPLAY Pilot display...
Page 102 EXPLANATION OF COMPONENTS OPERATION (15) Torque converter lockup pilot lamp (21) Aftertreatment devices regeneration pilot lamp (16) Shift hold pilot lamp (21) Aftertreatment devices regeneration disable pilot lamp (17) Preheating pilot lamp (22) ECO guidance (18) Fan reverse pilot lamp (23) DEF low level guidance (19) Power mode display (20) Secondary steering pilot lamp (if equipped)
Page 103 OPERATION EXPLANATION OF COMPONENTS CLEARANCE LAMP PILOT LAMP The clearance lamp pilot lamp lights up when the clearance lamps are turned on. AUTO-DIGGING PILOT LAMP The auto-digging pilot lamp lights up while the auto-digging function is enabled. AJSS PILOT LAMP (Machine with AJSS specification) AJSS pilot lamp is lit while the AJSS lever lock is canceled.
Page 104 EXPLANATION OF COMPONENTS OPERATION Remote positioner RAISE pilot lamp It lights up in green only in boom RAISE operation when the re- mote positioner is effective. Remote positioner LOWER pilot lamp It lights up in green only in boom LOWER operation when the remote positioner is effective.
Page 105 OPERATION EXPLANATION OF COMPONENTS Power mode It pops up when the setting of power mode is changed. RPM SET PILOT LAMP The RPM set pilot lamp lights up in green when RPM set is ef- fective. RPM set pilot lamp lights up in yellow when RPM set is effec- tive and it is canceled temporarily or it is in the auto-decelera- tion state.
Page 106 EXPLANATION OF COMPONENTS OPERATION AUTOMATIC SHIFT PILOT LAMP The automatic shift pilot lamp lights up when the automatic shift function is selected. Change the shift mode with the transmission shift mode selec- tor switch. It pops up when the mode is switched from the manual shift to automatic shift.
Page 107 For engine preheating, see “METHOD FOR STARTING EN- GINE (3-198)”. MESSAGE DISPLAY The message display lights up when there is a message from Komatsu. To read the message, see “CHECK MESSAGE (3-103)”. Lights up in green There is an unread message.
Page 108 EXPLANATION OF COMPONENTS OPERATION 12-hour system display The clock is displayed in 12-hour mode with am or pm. 24-hour system display The clock is displayed in 24-hour mode. 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 ADJUST- MENT (3-91)”.
Page 109 OPERATION EXPLANATION OF COMPONENTS AFTERTREATMENT DEVICES REGENERATION DISABLE PILOT LAMP Aftertreatment devices regeneration disable pilot lamp lights up when the aftertreatment devices are set not to be regenerated. REMARK Even if the aftertreatment devices regeneration is disabled, when the manual stationary regeneration is necessary, KDPF soot accumulation caution lamp lights up.
Page 110 EXPLANATION OF COMPONENTS OPERATION WORK EQUIPMENT LOCK PILOT LAMP The work equipment lock pilot lamp lights up when the work equipment is locked. It 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 111 OPERATION EXPLANATION OF COMPONENTS GUIDANCE TO AVOID HYDRAULIC RELIEF If the hydraulic equipment is relieved for 8 seconds or more during operation, the hydraulic relief limit message is displayed on the machine monitor. Stop unnecessary hydraulic relief. The hydraulic relief limit message goes out automatically after 10 seconds.
Page 112 EXPLANATION OF COMPONENTS OPERATION LOCKUP RECOMMENDATION GUIDANCE If the machine travels at a speed of 11.5 km/h or higher and at accelerator opening of 80 % or more for 20 seconds with the lockup switch is at OFF position, the notification of lockup rec- ommendation is displayed on the machine monitor.
Page 113 OPERATION EXPLANATION OF COMPONENTS 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 114 EXPLANATION OF COMPONENTS OPERATION FUEL GAUGE Fuel gauge shows the amount of fuel in the fuel tank. If the indicator is in red range (C), the fuel level caution lamp lights up in red. The fuel level is 120 ℓ or below. Check the fuel level, and add fuel.
Page 115 OPERATION EXPLANATION OF COMPONENTS Service meter display Indicates the integrated operating hours of the machine. When the engine has run, the service meter advances even if the machine is not being operated. The service meter advances by 0.1 for 6 minutes of engine run- ning and by 1 for 1 hour of engine running, regardless of the engine speed.
Page 116 EXPLANATION OF COMPONENTS OPERATION Fuel consumption gauge display Indicates the average fuel consumption of the machine. One day display Displays the average fuel consumption of a day (from 0:00 a.m. of the day to 0:00 a.m. of the next day). Split (under measurement) display Displays the split fuel consumption under measurement.
Page 117 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 118 EXPLANATION OF COMPONENTS OPERATION REMARK • The switches effective 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 119 OPERATION EXPLANATION OF COMPONENTS RETURN SWITCH Pressing the return switch cancels a selection or changes, and returns the screen to the previous screen or the standard screen. UP SWITCH Pressing the up switch moves the cursor up by one item. When on the top line, the cursor moves to the bottom line.
Page 120 EXPLANATION OF COMPONENTS OPERATION Press the air conditioner switch and numeral key to enter numerals 0 to 9, which is indicated at the lower right of each switch. For details of other air conditioner switch and numeral key functions, see the explanation for each screen in “USER MENU (3-52)”.
Page 121 OPERATION EXPLANATION OF COMPONENTS (b) “Load Meter” (if equipped) • Setting for “Handled Material Selection” • Setting for “Addition or Subtraction Mode Select” • “Target Production Setting” • “Production Display and Reset” • “Total Load Weight” • “Calibration” • “Load Meter Display” •...
Page 122 EXPLANATION OF COMPONENTS OPERATION (g) “Monitor Setting” • “Rearview Monitor Setting” • “Meter Display Selection” • “Screen Adjustment” • “Clock Adjustment” • “Language Setting” • “Operator ID” (h) Message display • Check of message contents and reply to message On the user menu screen, it is possible to perform the following operations with the switches.
Page 123 OPERATION EXPLANATION OF COMPONENTS REMARK The default tab when the standard screen is changed to the user menu screen varies with the machine condi- tion. If multiple conditions are established simultaneously, the following priority is given. 1. KDPF event occurs → “Aftertreatment Devices Regeneration” 2.
Page 124 EXPLANATION OF COMPONENTS OPERATION Operations on “Operation Records” screen When “Average Fuel Consumption Display” is set to “1 Day” “1 Day” is displayed on the place shown with arrow in “Opera- tion Records” screen. You can perform the following operations with switches (1) to (3) on the switch panel.
Page 125 OPERATION EXPLANATION OF COMPONENTS (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 (4). You can perform the following operations with switches (1) to (4) on the switch panel.
Page 126 EXPLANATION OF COMPONENTS OPERATION Operations on “ECO Guidance Records” screen When “Average Fuel Consumption Display” is set to “1 Day” “1 Day” is displayed on the place shown with arrow in “ECO Guidance Records” screen. You can perform the following operations with switches (1) to (3) on the switch panel.
Page 127 OPERATION EXPLANATION OF COMPONENTS (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 (4). You can perform the following operations with switches (1) to (4) on the switch panel.
Page 128 EXPLANATION OF COMPONENTS OPERATION Operations on “Average Fuel Consumption Record” screen You can perform the following operations with switches (3) to (5) on the switch panel. (3) RETURN switch Returns to “Energy Saving Guidance” menu screen. (4) ENTER switch Clears the graph data. (5) Menu switch Switches graphical displays of the average fuel consumption.
Page 129 OPERATION EXPLANATION OF COMPONENTS Deleting “Average Fuel Consumption Record” When ENTER switch (4) is pressed, the confirmation screen is displayed. When ENTER switch (4) is pressed, graphs of data of “Last 12 hours” and “Last 7 days” are both deleted, and the screen returns to “Average Fuel Consumption Record”...
Page 130 EXPLANATION OF COMPONENTS OPERATION SET DISPLAY OF FUEL CONSUMPTION GAUGE The display of the fuel consumption gauge can be set to the value on daily basis or during split measurement period. Select “Average Fuel Consumption Display” from “Configu- rations” menu screen, then press ENTER switch (4). Select “1 Day”...
Page 131 OPERATION EXPLANATION OF COMPONENTS When on the last line, it moves to the first line. (3) RETURN switch Cancels the selected change and returns the screen to “Configurations” menu screen. (4) ENTER switch Allocates the selected change, and returns the screen to “Configurations” menu screen. REMARK Setting of “1 Day”...
Page 132 EXPLANATION OF COMPONENTS OPERATION When on the first line, it moves to the last line. (2) DOWN switch Moves to the next item (1 line below). When on the last line, it moves to the first line. (3) RETURN switch Cancels the selected change and returns the screen to “Configurations”...
Page 133 OPERATION EXPLANATION OF COMPONENTS Use UP switch (1) or DOWN switch (2) to set the value, then press ENTER switch (4). You can perform the following operations with switches (1) to (4) on the switch panel. (1) UP switch Increases the target fuel consumption value by 1 ℓ/h. (2) DOWN switch Decreases the target fuel consumption value by 1 ℓ/h.
Page 134 EXPLANATION OF COMPONENTS OPERATION “ECO Guidance Display” screen is displayed. Select “ON” or “OFF”, then press ENTER switch (4). “ON” Displays the ECO guidance. “OFF” Does not display the ECO guidance. You can perform the following operations with switches (1) to (4) on the switch panel.
Page 135 OPERATION EXPLANATION OF COMPONENTS Select “ECO Guidance Display at Key OFF” from “Configu- rations” menu, then press ENTER switch (4). “ECO Guidance Display at Key OFF” screen is displayed. Select “ON” or “OFF”, then press ENTER switch (4). “ON” Displays the operational advice on the end screen. “OFF”...
Page 136 EXPLANATION OF COMPONENTS OPERATION Each item of “Load Meter” menu screen is for settings and op- erations of the load meter. For details of load meter, see “HANDLE LOAD METER (6-44)”. MACHINE SETTINGS On each item of “Machine Setting and Information” menu screen, setting related to the machine can be per- formed.
Page 137 OPERATION EXPLANATION OF COMPONENTS Select “Fan Reverse Mode” on “Machine Setting and Infor- mation” menu screen, then press ENTER switch (4). “Fan Reverse Mode” screen is displayed. Press ENTER switch (4) to rotate the fan in reverse. When the conditions are satisfied, the fan rotates in reverse and the screen returns to the standard screen.
Page 138 EXPLANATION OF COMPONENTS OPERATION Select “Tilt Shock Reduction Level” on “Machine Setting and Information” menu screen, then press ENTER switch (4). “Tilt Shock Reduction Level” screen is displayed. Select a level on “Tilt Shock Reduction Level” screen as shown in the figure, then press ENTER switch (4). “OFF”...
Page 139 OPERATION EXPLANATION OF COMPONENTS With the dump shock reduction function, the shock can be reduced by decreasing the speed around the DUMP end. On “Dump Shock Reduction Level” screen, you can select the dump shock reduction level as you like. Select “Dump Shock Reduction Level”...
Page 140 EXPLANATION OF COMPONENTS OPERATION SELECT AUTO-DIGGING MODE On “Auto Digging Mode Selection” screen, “ON” or “OFF” of the auto-digging function can be selected. For details of the auto-digging, see “AUTO-DIGGING (3-221)”. Select “Auto Digging Mode Selection” on “Machine Setting and Information” menu screen, then press ENTER switch (4).
Page 141 OPERATION EXPLANATION OF COMPONENTS Select “Bucket Level Position Selection” on “Machine Set- ting and Information” menu screen, then press ENTER switch (4). “Bucket Level Position Selection” screen is displayed. On “Bucket Level Position Selection” screen, you can set the level position according to the bucket by selecting the type from “A”...
Page 142 EXPLANATION OF COMPONENTS OPERATION Select a type of bucket whose level position is to be ad- justed from the “Bucket Level Position Selection” screen, then press menu switch (5). “Bucket Level Position Selection” screen is switched. Select the “Bucket Level Position Adjustment”, press EN- TER switch (4), and then the adjustment mode starts.
Page 143 OPERATION EXPLANATION OF COMPONENTS According to the screen instructions, raise the boom to the highest position. If it is done successfully, the bucket level position has been adjusted and the screen returns to “Bucket Level Position Selection” screen. REMARK • When canceling the adjustment, press RETURN switch (3).
Page 144 EXPLANATION OF COMPONENTS OPERATION “Bucket Level Position Selection” screen is switched. Select “Bucket Level Position Initialization”, press ENTER switch (4), and then the initialization starts. You can perform the following operations with switches (1) to (4) on the switch panel. (1) UP switch Moves to the previous item (1 line above).
Page 145 OPERATION EXPLANATION OF COMPONENTS “Auto Kick Down Setting” screen is displayed. Select “ON” or “OFF”, then press ENTER switch (4). “ON” The auto-kickdown actuates. “OFF” The auto-kickdown does not actuate. It is possible to perform the following operations with switches (1) to (4) on the switch panel. (1) UP switch Moves to the previous item (1 line above).
Page 146 EXPLANATION OF COMPONENTS OPERATION “Auto-deceleration Setting” screen is displayed. Select either “ON” or “OFF”, then press ENTER switch (4). “ON” The auto-deceleration actuates. “OFF” The auto-deceleration does not actuate. You can perform the following operations with switches (1) to (4) on the switch panel. (1) UP switch Moves to the previous item (1 line above).
Page 147 OPERATION EXPLANATION OF COMPONENTS Method for resetting “Trip Meter” Select “Trip Meter” on “Machine Setting and Information” menu screen, then press ENTER switch (4). The screen changes to “Trip Meter” resetting confirmation screen. Press ENTER switch (4) to reset “Trip Meter”, and then the screen returns to “Machine Setting and Information”...
Page 148 EXPLANATION OF COMPONENTS OPERATION Select “Auto Idle Stop Timer Setting” on “Machine Setting and Information” menu screen, then press ENTER switch (4). “Auto Idle Stop Timer Setting” screen is displayed. Select the operation time on the “Auto Idle Stop Timer Set- ting”...
Page 149 For details of the aftertreatment devices regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-143)”. The operation methods and the contents of the display of KDPF regeneration and urea SCR regeneration are common.
Page 150 If any item is displayed in red, perform the maintenance for it immediately. REMARK The replacement intervals in “Air Cleaner Cleaning or Change” and “Coolant Change” are not set initially. If you want to change the setting for the maintenance interval and the maintenance notice time, consult your Komatsu distributor. 3-82...
Page 151 (6), then press ENTER switch (4). REMARK For the setting, changing, or canceling the password, ask your Komatsu distributor. Screen changes to “Maintenance Due Time Reset” screen. Press ENTER switch (4) on “Maintenance Due Time Re- set” screen, the screen changes to reconfirmation screen for “Maintenance Due Time Reset”.
Page 152 EXPLANATION OF COMPONENTS OPERATION Press ENTER switch (4) again on reconfirmation screen for “Maintenance Due Time Reset”, the remaining time is reset and the screen returns to “Maintenance” menu screen. REMARK • When reset is not necessary, press RETURN switch (3).
Page 153 OPERATION EXPLANATION OF COMPONENTS “Rearview Monitor Setting” menu screen is displayed. You can perform the following operations with switches (1) to (4) on the switch panel. (1) UP switch Moves to the previous item (1 line above). When on the first line, it moves to the last line. (2) DOWN switch Moves to the next item (1 line below).
Page 154 EXPLANATION OF COMPONENTS OPERATION (2) DOWN switch Moves to the next item (1 line below). When on the last line, it moves to the first line. (3) RETURN switch Cancels the selected change, and returns the screen to “Rearview Monitor Setting” menu screen. (4) ENTER switch Allocates the selected change, and returns the screen to “Rearview Monitor Setting”...
Page 155 OPERATION EXPLANATION OF COMPONENTS (2) DOWN switch Moves to the next item (1 line below). When on the last line, it moves to the first line. (3) RETURN switch Cancels the selected setting, and returns the screen to “Rearview Monitor Setting” menu screen. (4) ENTER switch Allocates the selected setting, and returns the screen to “Rearview Monitor Setting”...
Page 156 EXPLANATION OF COMPONENTS OPERATION “Meter Display Selection” menu screen is displayed. You can perform the following operations with switches (1) to (4) on the switch panel. (1) UP switch Moves to the previous item (1 line above). When on the first line, it moves to the last line. (2) DOWN switch Moves to the next item (1 line below).
Page 157 OPERATION EXPLANATION OF COMPONENTS (1) UP switch Moves to the previous item (1 line above). When on the first line, it moves to the last line. (2) DOWN switch Moves to the next item (1 line below). When on the last line, it moves to the first line. (3) RETURN switch Cancels the selected item, and returns the screen to “Meter Display Selection”...
Page 158 EXPLANATION OF COMPONENTS OPERATION You can perform the following operations with switches (1) to (4) on the switch panel. (1) UP switch Moves to the previous item (1 line above). When on the first line, it moves to the last line. (2) DOWN switch Moves to the next item (1 line below).
Page 159 OPERATION EXPLANATION OF COMPONENTS (3) RETURN switch Cancels the change and returns the screen to “Monitor Setting” menu screen. (4) ENTER switch Allocates the change, and returns the screen to “Monitor Setting” menu screen. (5) Menu switch The brightness returns to default. REMARK •...
Page 160 EXPLANATION OF COMPONENTS OPERATION When on the first line, it moves to the last line. (2) DOWN switch Moves to the next item (1 line below). When on the last line, it moves to the first line. (3) RETURN switch Returns the screen to “Monitor Setting”...
Page 161 OPERATION EXPLANATION OF COMPONENTS (2) DOWN switch Moves to the next item (1 line below). When on the last line, it moves to the first line. (3) RETURN switch Cancels the selected setting, and returns the screen to “Clock Adjustment” menu screen. (4) ENTER switch Allocates the selected setting, and returns the screen to “Clock Adjustment”...
Page 162 EXPLANATION OF COMPONENTS OPERATION (4) ENTER switch Proceeds to setting for month. When month display (B) is highlighted in yellow, operate the switches as follows to change month display. When it is not necessary to change the month setting, press ENTER switch (4). (1) UP switch Advances the numeral by 1.
Page 163 OPERATION EXPLANATION OF COMPONENTS Select “Time” from “Clock Adjustment” menu screen, then press ENTER switch (4). “Time” screen is displayed. When time display (D) is highlighted in yellow, operate the switches as follows to change time display. When it is not necessary to change the time setting, press ENTER switch (4).
Page 164 EXPLANATION OF COMPONENTS OPERATION Select “12hour or 24hour Mode” from “Clock Adjustment” menu screen, then press ENTER switch (4). “12hour or 24hour Mode” screen is displayed. Select “12hour” or “24hour”, then press ENTER switch (4). “12hour” Select 12-hour display (AM, PM). “24hour”...
Page 165 OPERATION EXPLANATION OF COMPONENTS Select “Daylight Saving Time” from “Clock Adjustment” menu screen, then press ENTER switch (4). “Daylight Saving Time” screen is displayed. “ON” The clock is displayed in daylight saving time (summer time). Displays the time 1 hour forward. “OFF”...
Page 166 On “Operator ID” screen, you can check and change “Operator ID” which is under identification. When the operator identification function is disabled, “Operator ID” screen is not displayed on “Monitor Setting” menu screen. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi- fication function. 3-98...
Page 167 OPERATION EXPLANATION OF COMPONENTS WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted, the identified ID is displayed in the column of “Operator ID” on “Monitor Set- ting” menu screen. When the starting switch is ON and “SKIP” is selected, “****” is displayed in the column of “Operator ID”...
Page 168 EXPLANATION OF COMPONENTS OPERATION • Input the already registered ID on “Operator ID Change” screen by using the numeric keypad (6), and press ENTER switch (4). A message is displayed below, the screen returns to “Monitor Setting” menu screen, and the identified ID is changed.
Page 169 OPERATION EXPLANATION OF COMPONENTS “Operator ID Change” screen is displayed. REMARK When the ID change is not necessary, press RETURN switch (3). • Input the already registered ID on “Operator ID Change” screen by using the numeric keypad (6), and press ENTER switch (4).
Page 170 On machines equipped with KOMTRAX, when message pilot lamp is lit on the standard screen, you can see the messages from your Komatsu distributor on the mail check menu screen by pressing the menu switch. Message is distinguished as follows according to the lighting states of the message display.
Page 171 • When the message display lights up in blue, it means that no reply has been made yet to any read mes- sage to your Komatsu distributor. Reply to the message in accordance with the replying method mentioned below. •...
Page 172 EXPLANATION OF COMPONENTS OPERATION When “Do you send Numeric Input?” is displayed, press ENTER switch (4) again. The input value will be sent out. REMARK To cancel the transmission, press RETURN switch (3). The input value is cleared. REMARK If the message is replied, “Numeric Input (Done)” is displayed for it.
Page 173: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES 3-105...
Page 174 EXPLANATION OF COMPONENTS OPERATION (1) Directional selector switch (19) Revolving lamp switch (if equipped) (2) Horn switch (20) Working lamp switch (3) Downshift switch (21) Rear heated wire glass switch (4) Upshift switch (22) Secondary parking brake release switch (5) Engine shutdown secondary switch (23) Modulation clutch engagement switch (6) Hazard lamp switch (24) Load meter sub total switch (if equipped)
Page 175 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH Starting switch is used to start or stop the engine. (A) OFF position The electrical current to the electrical system is cut off, the en- gine stops, and the parking brake is automatically applied. The key can be inserted into or removed from the starting switch.
Page 176 EXPLANATION OF COMPONENTS OPERATION LAMP SWITCH The lamp switch is used to light up the headlamps, clearance lamps, tail lamps, and machine monitor. (a) OFF position The lamps go out. (b) ON position The clearance lamps, tail lamps, and machine monitor light up. (c) ON (headlamp lighting) position The clearance lamps, tail lamps, headlamps, and machine monitor light up.
Page 177 OPERATION EXPLANATION OF COMPONENTS The front wiper and window washer switch is used to operate the wiper of the front glass. Turn the wiper and window washer switch (A) to operate the front wiper. Position (a) (OFF) The front wiper stops. Position (b) (INT) The front wiper operates at intervals of 4 to 7 seconds.
Page 178 EXPLANATION OF COMPONENTS OPERATION This function facilitates the load-and-carry operation. • When the travel speed is 12.5 km/h or higher, the gear speed is shifted down by one gear speed each time the kickdown switch is pressed as F4, F3, and F2 in this order. •...
Page 179 OPERATION EXPLANATION OF COMPONENTS (a) OFF position All working lamps go out. (b) REAR position Rear working lamp (A) lights up. (c) FRONT (&SIDE) position Front working lamp (B), side front working lamps (C) (if equip- ped), and front lower working lamps (D) (if equipped) light up. (d) ALL position All working lamps light up.
Page 180 Stop the machine, and then apply the parking brake. If the parking brake was used as a secondary brake when the machine was traveling, ask your Komatsu distributor for inspection of the parking brake system.
Page 181 OPERATION EXPLANATION OF COMPONENTS The parking brake switch is used to apply and release the park- ing brake. (a) ON position The parking brake is applied. When the parking brake switch is set to ON position (a), the parking brake pilot lamp lights up on the machine monitor. When the parking brake switch is shifted to ON position (a), if the directional lever or directional selector switch is in the posi- tion other than NEUTRAL position (N), the centralized warning...
Page 182 EXPLANATION OF COMPONENTS OPERATION HOLD SWITCH The gear speed is fixed or the fixed gear speed is canceled each time when the hold switch is pressed. When the hold switch is pressed, the gear speed is fixed to the gear speed indicated on the shift indicator of the machine mon- itor, and the shift hold pilot lamp lights up.
Page 183 OPERATION EXPLANATION OF COMPONENTS The room lamp switch is used to turn on or off the room lamp. (a) ON position The room lamp lights up. (b) ON position The room lamp lights up when the cab door is opened. (c) OFF position The room lamp goes out.
Page 184 EXPLANATION OF COMPONENTS OPERATION REMARK • The ECSS system absorbs the machine vibration during travel with the hydraulic effect of the accumulator to attain smooth high speed travel. • The ECSS does not operate in 1st gear speed. • If the travel speed becomes 5 km/h or higher while the gear speed is 2nd to 4th, the ECSS operates auto- matically.
Page 185 If you want to make any change to the setting at the engine start, consult your Komatsu distributor. TRANSMISSION SHIFT MODE SELECTOR SWITCH The transmission shift mode selector switch is used to switch the transmission between the automatic shift and manual shift.
Page 186 EXPLANATION OF COMPONENTS OPERATION REMARK • On the slippery road such as muddy surface, slipping of the tire can be prevented by setting the driving force to be decreased with the driving force control dial beforehand. Change the setting for the driving force according to the condition of the work place, workability, and a state of the road surface.
Page 187 OPERATION EXPLANATION OF COMPONENTS TORQUE CONVERTER LOCKUP SWITCH The torque converter lockup switch is used to turn on and off the torque converter lockup function. (a) ON position The torque converter lockup operates according to the travel speed and working condition. (b) OFF position The torque converter lockup does not operate.
Page 188 EXPLANATION OF COMPONENTS OPERATION WORK EQUIPMENT LOCK SWITCH WARNING • Before standing up from the operator's seat or when adjusting the position of the operator's seat, securely press the work equipment lock switch to lock the work equipment, and make the work equipment lock pilot lamp light up.
Page 189 OPERATION EXPLANATION OF COMPONENTS Manual shift There are 4 gear speeds in forward and reverse. The gear speed can be changed by pressing the gear speed switch. When performing the operation, use the 1st and 2nd. When driving the machine, use the 3rd and 4th. (a) Upshift switch Upshifts the gear speed.
Page 190 EXPLANATION OF COMPONENTS OPERATION Press the hold switch to fix the gear speed. The gear speed is fixed to the one indicated in the shift po- sition display on the machine monitor. Change the fixed gear speed with the gear speed switch. Press the hold switch again to cancel the fixed gear speed.
Page 191 OPERATION EXPLANATION OF COMPONENTS • When the starting switch is turned to ON position while the engine shutdown secondary switch is in “EN- GINE STOP” position, “Engine Shutdown Secondary SW in Operation” is displayed on the machine monitor. If this screen is displayed, return the engine shutdown secondary switch to “NORMAL”...
Page 192: Control Levers And Pedals
EXPLANATION OF COMPONENTS OPERATION Staircase lighting switch at the step REMARK The staircase lighting lights up even when the starting switch is at OFF position. Always turn off the staircase lighting when leaving the machine, otherwise the battery will be consumed. CONTROL LEVERS AND PEDALS (1) AJSS lever (5) Accelerator pedal...
Page 193 OPERATION EXPLANATION OF COMPONENTS The steering lock lever is a locking device for the AJSS lever. (L) LOCK position The AJSS lever is locked. The AJSS lever is not operable. (F) FREE position The AJSS lever is unlocked. The AJSS lever is operable. BRAKE PEDAL WARNING •...
Page 194 EXPLANATION OF COMPONENTS OPERATION L.H. brake pedal Operates the wheel brake, and decreases the driving force at the same time. (A) Driving force (B) Braking force (Y): L.H. brake stroke ( %) REMARK • Use the L.H. brake pedal when operating the work equip- ment while accelerating and decelerating the machine by using the brake and accelerator.
Page 195 OPERATION EXPLANATION OF COMPONENTS The bucket control lever is used to operate the bucket. (a) “TILT” position If the bucket control lever is pulled further from “TILT” position (a), it stops at “detent” position (d). It stops at the set position of the remote bucket positioner and the bucket control lever returns to “HOLD”...
Page 196: Other Equipment
EXPLANATION OF COMPONENTS OPERATION AJSS LEVER WARNING Always set the steering lock lever in LOCK position before leaving the operator's seat while the engine is running. The AJSS lever is used to steer the machine. Tilt the AJSS lever in the direction of the turn during traveling, then the machine turns.
Page 197 OPERATION EXPLANATION OF COMPONENTS OPEN KNOB FOR CAB DOOR Pull the open knob for the cab door, and the cab door opens to the full open position. UNLOCK KNOB FOR WINDOW OF CAB DOOR Unlock knob for window of cab door is used to open and close the cab door window.
Page 198 EXPLANATION OF COMPONENTS OPERATION Alternate exit door completely closed and locked state If the open knob (1) of the alternate exit of cab is completely pushed down, it is completely closed and locked. Normally, it must be completely closed and locked when oper- ating the machine.
Page 199 OPERATION EXPLANATION OF COMPONENTS Remove the guide rail part of the open knob (1) for alter- nate exit of cab from guide pin (2). The alternate exit door is unlocked. Open the door of the alternate exit. Open the door of the alternate exit fully. Open the door of the alternate exit fully, and get off from the machine.
Page 200 EXPLANATION OF COMPONENTS OPERATION PROCEDURE FOR LOCKING ALTERNATE EXIT OF CAB NOTICE If the door is closed without holding the open knob (1) for alternate exit of cab, the plastic part of the door knob hits against guide pin (2) on the cab side, and the plastic part of the open knob (1) for alternate exit of cab may break.
Page 201 OPERATION EXPLANATION OF COMPONENTS LUNCH BOX TRAY There is a space for a lunch box on the rear right of the opera- tor's seat. A band is provided to fasten the lunch box. This has enough room for a lunch box with dimensions of 35 cm length, 22 cm width, 18 cm height.
Page 202 EXPLANATION OF COMPONENTS OPERATION When cigarette lighter (1) is removed, its socket can be used as a 24 V power supply. The maximum capacity is 85 W (24 V x 3.5 A). REMARK Use 24 V power supply while engine is running. 12 V power supply Power supply outlet (2) can be used as a 12 V power supply.
Page 203 OPERATION EXPLANATION OF COMPONENTS Fuse capacities and circuit names Fuse box A Fuse Name of circuit capacity 5 A Air conditioner 10 A Grease (if equipped) 5 A Staircase lighting 10 A Hazard lamp 20 A Dozing pump 5 A Room lamp 10 A KOMTRAX Plus controller 10 A Main monitor 5 A...
Page 204 EXPLANATION OF COMPONENTS OPERATION Fuse box C Fuse Name of circuit capacity (31) 5 A Air conditioner compressor (32) 20 A Spare (33) 20 A Air conditioner blower (34) 10 A Optional (35) 10 A Optional (36) 10 A Preheat (37) 10 A Spare (38) 5 A Monitor main (39) 5 A Secondary parking brake...
Page 205 OPERATION EXPLANATION OF COMPONENTS Frame lock bar lock pin WARNING Insert the frame lock bar lock pin securely, and apply the linch pin. If the insertion is insufficient, the pin may come off or the frame lock bar may be deformed, and it is dangerous. Fix the frame lock bar lock pin (1) as follows.
Page 206 EXPLANATION OF COMPONENTS OPERATION TOOL BOX The toolbox is inside the step on the rear right of the machine. HANDLE REAR FENDER (if equipped) The rear fender on the rear right of the machine protects the machine and the surrounding against mud. GREASE PUMP HOLDER The grease pump holder is inside the side cover of radiator guard on the left side of the machine.
Page 207 OPERATION EXPLANATION OF COMPONENTS BATTERY DISCONNECT SWITCH CAUTION • Do not operate the battery disconnect switch while the engine is running. The large current generated by the alternator may burn the electric parts and cause a fire. Operate the battery disconnect switch only when the engine is stopped. •...
Page 208 After the starting switch has been turned to OFF position, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. HANDLE AUXILIARY ENGINE STARTING CONNECTOR The SAEJ1283 compliant auxiliary engine starting connector is provided for this machine.
Page 209 Operating effort of the reset button becomes larger when the circuit is open than when the circuit is not open. If the operating effort is still large after the reset button has been pushed in, the electrical circuit may be open. In such case, ask your Komatsu distributor for repair. 3-141...
Page 210 EXPLANATION OF COMPONENTS OPERATION DUST INDICATOR This device indicates clogging of the air cleaner. Depending on the degree of clogging of the element, red line (1) appears in the transparent portion. line indicates 7.5 kPa INCHES {0.076 kg/cm }, clean the element immediately. After cleaning, press the top part (2) of the indicator, and the red line (1) returns to its original position.
Page 211 The guide line dose not synchronize with steering angle. The guide line does not indicate the actual moving direc- tion or travel path. HANDLE Komatsu Diesel Particulate Filter (KDPF) CAUTION • Exhaust gas temperature may increase during the aftertreatment devices regeneration and the high temperature may last after the completion of regeneration.
Page 212 EXPLANATION OF COMPONENTS OPERATION REMARK • Even if aftertreatment devices regeneration pilot lamp (1) lights up, the machine does not need to be stopped and the work can be continued, unless when the KDPF soot accumulation caution lamp (2) lights up. •...
Page 213 Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may cause failure.
Page 214 EXPLANATION OF COMPONENTS OPERATION When the degree of emergency is low • If KDPF soot accumulation caution lamp (2) lights up in yellow (action level (4): “L01”), screen (A) is displayed first. • The action level goes out 2 seconds after and the screen changes to standard screen (B).
Page 215 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR MANUAL STATIONARY REGENERATION CAUTION Exhaust gas temperature may increase during the aftertreatment devices regeneration and the high temperature may last after the completion of regeneration. Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt. Keep combustible materials away from the exhaust pipe outlet and around the aftertreatment devices to prevent a fire.
Page 216 EXPLANATION OF COMPONENTS OPERATION Press the menu switch to display “Aftertreatment Devices Regeneration” screen. Select the manual stationary regeneration, check again safety of the area around the machine 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 the safety, move it to a safe place and repeat the proce- dure from step 1.
Page 217 OPERATION EXPLANATION OF COMPONENTS This screen is displayed during the manual stationary re- generation. It may take more than 30 minutes to complete the manual stationary regeneration. Do not touch any switch on the screen or accelerator pedal until the regener- ation is completed and the standard screen is displayed again.
Page 218 EXPLANATION OF COMPONENTS OPERATION WHILE REGENERATION IS NOT BEING PERFORMED: SETTING FOR REGENER- ATION DISABLE (When the aftertreatment devices regeneration is not displayed on the standard screen) Press the menu switch on the standard screen. Press the menu switch to select “Aftertreatment Devices Regeneration”...
Page 219 OPERATION EXPLANATION OF COMPONENTS When the menu switch is pressed on the standard screen, “Aftertreatment Devices Regeneration” screen is dis- played. Select the regeneration disable and press ENTER switch, and then the regeneration stops. REMARK The regeneration for protection of the system in cold weather may not be stopped, but this is not a failure.
Page 220 Urea SCR systems by utiliz- ing visible and audible alerts , and engine power derate in addition. Alerts in Inducement of the Komatsu Urea SCR System progresses step by step starting from visual indications on the machine monitor and audible sounds to engine power derate to avoid getting into unsafe conditions.
Page 221 In addition, it may cause fail- ures in the engine system. If DEF out of the standard is filled or used by mistake, contact your Komatsu dis- tributor. About the operation of Urea SCR system The Urea SCR System automatically starts operating as soon as the engine is started.
Page 222 EXPLANATION OF COMPONENTS OPERATION and injection while heating continues. Once the ambient temperature rises above a temperature where DEF system becomes functional, it resumes operation automatically. Short duration of white plume given off from the tail pipe may be visible at and shortly after engine start-up in cold weather, but this is not malfunction.
Page 223 OPERATION EXPLANATION OF COMPONENTS Inducement status (4): “1 DEF low level warning appears.” Add DEF to the DEF tank immediately. • Continuous Warning: The audible alert sounds in “Intermittent alarm”. 2 gradations of the DEF level gauge light up in the red range.
Page 224 “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 Information” screen of the user menu.
Page 225 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen displays remaining time to the next Inducement status in the column (5), and information on the Urea SCR System condition (3), and the current status of In- ducement (4). • Warning: No audible alert. The DEF system caution lamp (1) lights up in yellow.
Page 226 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 227 “Severe Inducement”, the engine power will be further derated. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 228 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen message (5): “1 Please inspect and maintain SCR system.” Engine power is derated. Move the machine to the safe place and contact your Ko- matsu Distributor. If operation continues for 5 hour after “Warning” started without taking any actions instructed by the Action Level table, Inducement advances to “Continuous Warning”.
Page 229 Komatsu distributor. Inducement strategy when abnormality is found in the EGR Valve System by the...
Page 230 EXPLANATION OF COMPONENTS OPERATION Perform the following procedure. Press the menu switch to display the “SCR Information” screen. After a lapse of 3 seconds to stop the machine, “SCR Informa- tion” screen is displayed. “SCR Information” screen displays remaining time to the next Inducement status in the column (6), and information on the Urea SCR System condition (4), and the current status of In- ducement (5).
Page 231 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen message (5): “2 Without treat- ment, engine power will be derated.” Move the machine to the safe place and contact your Ko- matsu Distributor. The duration time of “Continuous Warning” is 5 hour. The remaining time (Minutes) till the next Inducement status of “Low level Inducement”...
Page 232 “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 the one of the Inducement strategies allowed to be included in Urea SCR systems.
Page 233 OPERATION EXPLANATION OF COMPONENTS Press the enter switch (2) while the pop-up menu screen B is displayed. The “Engine power Recovery” window pops up. If the enter switch (2) is not pressed for 30 seconds, “Standard Screen” will be displayed, and start again by pressing the menu switch (1).
Page 234 Inducement. If this occurs, utilize “Temporary Restoration from Inducement” and move to the machine to a safe place, and contact your Komatsu distributor. The maximum duration of power restoration is 30 minutes and 3 operations are allowed.
Page 235 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 236: 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 237 OPERATION MACHINE OPERATIONS AND CONTROLS 11. Check brake line for oil leakage. Check for leakage of oil or damage to the hoses and tubes. If any problem is found, repair it. 12. Check the tires, wheels, and wheel hub bolts and nuts for damage and wear, and check the wheel hub bolts and nuts for looseness.
Page 238 MACHINE OPERATIONS AND CONTROLS OPERATION 19. Check the seat belt and mounting hardware. WARNING Even if no problem can be seen on the appearance of the seat belt, replace it in accordance with the follow- ing schedule whichever date comes sooner. 5 years after the date of seat belt manufacture, or ev- ery 3 years after the start of actual usage.
Page 239 OPERATION MACHINE OPERATIONS AND CONTROLS WARNING If worn or damaged tires are used, they may burst and cause serious injury or death. To ensure safety, do not use the following tires. Wear • Tires with the tread groove depth of 15 % or less of that of a new tire •...
Page 240 MACHINE OPERATIONS AND CONTROLS OPERATION Open engine side cover (1) on the right side of machine, and fix it with the rod and band. Water separator (2) is integrated with the fuel prefilter and located in the lower part. Check for water and sediment. The water level and amount of sediment can be judged by looking through transparent cup (3).
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS Open radiator guard side cover (1) on the left side of ma- chine, and fix it with the rod. Check reservoir tank (2). Check that the coolant level is between FULL and LOW marks of the sight gauge. If the coolant level is low, add Non-Amine Engine Coolant to FULL level through coolant filler port (3) of reservoir tank (2).
Page 242 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine. • The oil level can be checked when the engine is running at low idle as well. When checking in such condi- tion, observe the following.
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS Fully insert dipstick (G) into the dipstick pipe, then remove It is correct if the oil level is between marks H and L. The oil levels stamped on either side of the dipstick are for when the engine is stopped (ENGINE STOPPED) or when the engine is running at low idle (ENGINE IDLING).
Page 244 • 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 245 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the starting switch to ON position (B). Check the fuel level with fuel gauge (G). After checking, turn the starting switch back to OFF posi- tion (A). After operations are completed, open cover (1) for the fuel tank filler port and DEF tank filler port, and fix it with the bar.
Page 246 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the alarm buzzer sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and inspection. DEF injector and/or DEF pump may need to be replaced.
Page 247 OPERATION MACHINE OPERATIONS AND CONTROLS Open cover (2) for the fuel tank filler port and DEF tank fill- er port, and fix it with the bar. Turn the cap of filler port (3) counterclockwise. The cap of filler port is opened. While watching sight gauge (4), add DEF through the filler port until float (5) reaches line F (6).
Page 248 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 249 If the bulkhead and rubber sheet are damaged or falling off, ask your Komatsu distributor for repair. Check if bulkhead (1) and rubber sheet (2) between the engine compartment and hydraulic pump are damaged or falling off.
Page 250 Operate the fore-aft adjustment lever upward, set the seat to the desired position, then release the fore-aft adjustment lever. Adjustment amount: 152.4 mm {6 in} Number of stages for adjustment: 13 stages Adjustment amount per 1 stage: 12.7 mm If the seat backlash is found, ask your Komatsu distributor for adjustment. 3-182...
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR RECLINING SEAT Pull up the reclining adjustment lever, and move the back cush- ion forward or backward. Sit with your back against the backrest when adjusting the re- clining angle. If your back is not on the backrest, it may sud- denly return to the original position.
Page 252 Fore-aft adjustment range: 60 mm If the seat backlash is found, ask your Komatsu distributor for adjustment. METHOD FOR ADJUSTING HEADREST ANGLE Move the headrest back and forth to set it to the desired angle.
Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS Operate the air lumbar support adjustment switch to give a proper tension to the waist part. (a) Position for air inflation Air is pumped in the air bag in the backrest and the air bag is inflated.
Page 254 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the seat heater switch to ON position (a). The heater in the seat cushion operates, and the seat cushion and backrest become warm. Turn the seat heater switch to OFF position (b) when the temperature of cushion becomes suitable.
Page 255 OPERATION MACHINE OPERATIONS AND CONTROLS • When using the seat heater Set the seat heater and ventilation selector switch (1) to the position (a). Set the air flow control switch (2) to HIGH position (d) or LOW position (e). The heater in the seat cushion operates, and the seat cushion and backrest become warm.
Page 256 MACHINE OPERATIONS AND CONTROLS OPERATION CAUTION The following conditions must be met before starting the work to prevent the machine from moving dur- ing adjustment. • The machine is placed on a level ground. • The work equipment is lowered to the ground in secure posture. •...
Page 257 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 rearview camera. Check the rearview camera angle. Adjust the angle of the rearview camera so that people within approximately 1 m away (W) from the machine's...
Page 258 (A), and horizontal line (D) matches to position (B) that is 1.5 m away from the rear end of the machine. When the guide line is abnormal, change its setting to Non-display. Contact your Komatsu distributor. METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING •...
Page 259 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR UNFASTENING SEAT BELT When unfastening the seat belt, press the red button on buckle (2) to free the R.H. belt. REMARK If the seat belt is not locked, the seat belt caution lamp lights up on the machine monitor.
Page 260 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING LEVER STAND IN FORE-AND-AFT DIRECTION While pulling up fore-and-aft adjustment lever (3) of the lever stand with the left hand, hold armrest (1) with the right hand to adjust the lever stand to the desired position, and then release fore-and-aft adjustment lever (3).
Page 261 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING When starting the engine, securely press the work equip- ment lock switch to lock the work equipment, and make the work equipment lock pilot lamp light up. If the work equipment is not locked and work equipment control lever (A) is touched by mistake, it may lead to seri- ous accident.
Page 262 MACHINE OPERATIONS AND CONTROLS OPERATION Check that directional selector switch (4) is in NEUTRAL position (N). REMARK If the directional selector switch is not in NEUTRAL posi- tion (N), when turning the starting switch to ON position, the alarm buzzer sounds (in a period of 0.25 seconds), and the engine cannot be started.
Page 263 11. Check that machine monitor (5) operates as follows. NOTICE If the machine monitor does not light up, there may be a failure or wire breakage. Ask your Komatsu distribu- tor for inspection. Centralized warning lamp (10) and pilot display (11) are lit for 2 seconds and off for 1 second.
Page 264 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK In approximately a second, the rearview monitor dis- plays soft version for 5 seconds. If a password has been set, the password input screen will be displayed on the monitor screen. After inputting the password, press ENTER switch. REMARK For details of the password setting, changing or can- celing, see the separate “Password Change and Can-...
Page 265 OPERATION MACHINE OPERATIONS AND CONTROLS When the maintenance time caution lamp lights up in red, press the menu switch and “Maintenance” menu screen is displayed. For “Maintenance” menu screen and the remedies, see “MAINTENANCE SCREEN SETTING (3-82)”. Maintenance time caution lamp is lit for 30 seconds. 12.
Page 266: Method For Starting Engine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STARTING ENGINE METHOD FOR STARTING ENGINE IN NORMAL 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 267 OPERATION MACHINE OPERATIONS AND CONTROLS Engine coolant tem- Preheating time perature Variable between 0 0 to -25 °C and 45 seconds Max. -25 °C 45 seconds REMARK Usually, the engine is preheated sufficiently by the automatic preheating. If it is needed to extend the pre- heating time, turn the starting switch to preheating position (D).
Page 268 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE • Do not accelerate the engine abruptly until it is warmed up. • Do not turn the starting motor continuously for 20 sec- onds or longer. • If the engine does not start, wait for 2 minutes or so, and then try to start the engine again.
Page 269 OPERATION MACHINE OPERATIONS AND CONTROLS After preheating pilot lamp (2) goes out, turn starting switch (1) to START position (C). The starting motor rotates to start the engine. Keep the starting switch (1) at position (C) to keep running the starting motor until the engine starts. REMARK •...
Page 270: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 271 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 272 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE • Do not accelerate the engine abruptly until it is warmed up. • Do not run the engine at low idle or high idle with no load for 20 minutes or more. This will have an adverse effect on the environment and also on the internal structure of the engine.
Page 273: Method For Stopping Engine
If any problem is found, perform maintenance or repair. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. REMARK The cooling fan speed varies according to the following conditions, but it is not abnormal.
Page 274 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE Do not stop the engine abruptly except in an emergency. Otherwise, the service lives of component parts of the en- gine will be reduced. Allow the engine to cool down gradu- ally before stopping it. If the engine is overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradu- ally, and then stop it.
Page 275: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE METHOD FOR MOVING MACHINE WARNING • When driving the machine, always set the frame lock bar to FREE position. If the frame lock bar is not in FREE position, the steer- ing becomes inoperative and this may lead to serious personal injury or death.
Page 276 MACHINE OPERATIONS AND CONTROLS OPERATION Press (a) of work equipment lock switch (4) and unlock the work equipment. Make the work equipment lock pilot lamp on machine mon- itor (1) go out. Operate work equipment control levers (2) and (3) to set the work equipment to the travel posture and raise it to height (a) of 50 to 60 cm.
Page 277 OPERATION MACHINE OPERATIONS AND CONTROLS Set gear shift switch (8) to the desired position. (a) Upshift switch The range of automatic gear shit for the gear speed in- creases. (b) Downshift switch The range of automatic gear shit for the gear speed de- creases.
Page 278 Place directional selector switch (10) in REVERSE position (R), and check that the backup alarm sounds. If the backup alarm does not sound, ask your Komatsu distributor for repairs. 11. Release R.H. brake pedal (5), then depress accelerator pedal (11).
Page 279: Method For Shifting Gears
OPERATION MACHINE OPERATIONS AND CONTROLS Set directional selector switch (3) to NEUTRAL position (N). Set parking brake switch (4) to ON position (a), and apply the parking brake. When the parking brake has been applied, the parking brake pilot lamp lights up on machine monitor (5). REMARK When the parking brake switch is actuated, the transmis- sion becomes neutral state automatically.
Page 280 MACHINE OPERATIONS AND CONTROLS OPERATION Check the transmission shift mode with machine monitor (1) and transmission shift mode selector switch (2). Normally, set it to automatic shift (a). (a) Automatic shift Automatic shift is effective. Automatic shift pilot lamp lights up. (b) Manual shift Manual shift is effective.
Page 281 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • If the gear speed switch is operated slowly or is stop- ped between gear positions, the centralized warning lamp may light up and the alarm buzzer may sound, but this is not a failure. Operate the gear speed switch so that gear shifting is completed in 2 seconds.
Page 282: Method For Switching Between Forward And Reverse
(R) REVERSE position It is used to drive the machine in reverse. Place directional selector switch (1) in REVERSE position (R), and check that the backup alarm sounds. If the backup alarm does not sound, ask your Komatsu distributor for repairs. 3-214...
Page 283 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • If you operate the directional selector switch slowly or stop it at midway between the switching positions, the central- ized warning lamp may light up and the alarm buzzer may sound, but this is not a failure. Operate the directional selector switch so that the travel di- rection can be changed within 2 seconds.
Page 284: Method For Steering Machine
Check that the operation of steering system is normal. If any problem is found, ask your Komatsu distributor for inspection. Front and rear frames of this machine is articulated around the connection pin (center pin) at which the 2 frames are connected with each other and the rear wheels follow the trace of the front wheels.
Page 285 OPERATION MACHINE OPERATIONS AND CONTROLS CAUTION The secondary steering system does not operate while the machine is stopped. Even when the engine is stopping in an emergency, you can steer the machine if the secondary steering pilot lamp lights up in green.
Page 286 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE During the high-speed travels listed below, do not shift down the gear speed in order to prevent over- run. (The travel speed specified in this section may vary depending on the conditions of use or on road sur- face condition.) •...
Page 287: Method For Operating Work Equipment
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPERATING WORK EQUIPMENT WARNING • Before standing up from the operator's seat or when adjusting the position of the operator's seat, securely press the work equipment lock switch to lock the work equipment, and make the work equipment lock pilot lamp light up.
Page 288 MACHINE OPERATIONS AND CONTROLS OPERATION • Boom control lever (3) is used to control the boom. Operate boom control lever (3) back and forth. (a) “RAISE” position • When the RAISE remote boom positioner is set, if the boom control lever is pulled further from “RAISE”...
Page 289 OPERATION MACHINE OPERATIONS AND CONTROLS AUTO-DIGGING The auto-digging system controls the tilting operation of the bucket automatically to facilitate bucket operation and reduce the fatigue of the operator. When operating, see “DIGGING WORK (3-223)”. METHOD FOR AUTO-DIGGING While driving the machine forward, lower the bucket edge to height (a) of 30 cm or less above the ground.
Page 290: 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 291: Method For Checking Bucket Angle
• The most suitable tire pressure and travel speed differ according to the tire type and condition of the travel surface. Consult your Komatsu distributor or tire dealer. • The following shows the appropriate tire pressure and travel speed when the machine is equipped with standard tires and runs on the paved surface.
Page 292 MACHINE OPERATIONS AND CONTROLS OPERATION • Level the job site constantly and remove any fallen rocks. • 1st or 2nd gear speed is recommended for scooping stock piles and 1st gear speed for blasted rocks. When lowering the bucket while driving the machine for- ward, stop the bucket once at height (a), a position approx- imately 30 cm from the ground, then lower it further slowly.
Page 293 OPERATION MACHINE OPERATIONS AND CONTROLS Check that enough material is loaded into the bucket, then operate the bucket control lever to repeat tilting back the bucket and load the bucket fully. If the bucket edge is moved up and down while digging with the bucket by using rim pull, the front tires will come off the ground and this will cause the tire slippage.
Page 294 MACHINE OPERATIONS AND CONTROLS OPERATION While driving the machine forward, tilt the boom control lever slightly forward to dig bit by bit as earth and sand are peeled off. Keep on driving the machine forward while adjusting the digging depth by using the boom control lever. When you perform digging by use of the bucket, avoid ap- plying the digging force only to one side of the bucket.
Page 295 OPERATION MACHINE OPERATIONS AND CONTROLS LOAD-AND-CARRY OPERATION WARNING • When carrying a load, lower the bucket to lower the center of gravity of the machine and drive. • If the ECSS switch is turned to ON position during travel or with the work equipment raised, the machine starts moving instantly.
Page 296 MACHINE OPERATIONS AND CONTROLS OPERATION CROSS DRIVE LOADING When performing digging, set the wheel loader at a right angle to the target stock pile. After digging in and scooping up the load, drive the machine straight back in reverse, then bring the dump truck in between the stock pile and the wheel loader.
Page 297 OPERATION MACHINE OPERATIONS AND CONTROLS OPERATION PROCEDURES FOR AVOIDING DAMAGE ON MACHINE HANDLE BUCKET When lowering the bucket to the ground while approaching the working face, be sure not to lower it to the ground abruptly. Lowering the bucket abruptly gives large impacts to the bucket, work equipment, pins, and machine frame, causing damage or crack to them.
Page 298 MACHINE OPERATIONS AND CONTROLS OPERATION BUCKET DUMP ANGLE WHEN DIGGING OR CUTTING DOWN When performing digging or ground excavation, do not in- crease the angle between the bucket edge and ground. Make angle (a) between the bucket and ground to 8 ° or less. If you perform the digging or ground excavation with angle (a) between the bucket edge and ground to 8 °...
Page 299 OPERATION MACHINE OPERATIONS AND CONTROLS In digging or scooping work, thrust the center of bucket into the target material. BUCKET DUMP OPERATION WHEN DIGGING Do not operate the bucket to DUMP side during digging. If you operate the bucket to DUMP side during digging, the machine cannot travel forward, the tires slip, and a large load is applied on the work equipment.
Page 300 MACHINE OPERATIONS AND CONTROLS OPERATION HANDLE PUMICE STONE WARNING Do not use this machine to remove pumice stone. Pumice stone may fall onto the machine and operator's seat during removal of it. It may fall onto the operator's seat, causing a serious per- sonal injury or death.
Page 301 OPERATION MACHINE OPERATIONS AND CONTROLS STEER TIRES WITHOUT DRIVING Do not try to steer the machine (stationary steering) when it is stopped. Steering while the machine is stopped (stationary steering) induces wear and cuts on the tires. And it deteriorates durability of the frame and undercarriage.
Page 302 MACHINE OPERATIONS AND CONTROLS OPERATION Set the gear shift lever to FORWARD 2nd and depress the accelerator pedal gradually to increase the trav- el speed. Lower the bucket. At this time, decrease the bucket lowering speed when it comes close to the ground so that it touches the ground gently.
Page 303 OPERATION MACHINE OPERATIONS AND CONTROLS When the machine approaches close to rocks, release the accelerator pedal and shift down the travel speed from 2nd to 1st. After the shifting down, gradually depress the accelerator pedal to thrust the bucket into the rocks. Slightly raise the boom to allow front wheels to increase the driving force.
Page 304 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK Select the way of steering the machine according to the stop position of dump truck and the state of the muck. Determine the stop position of the dump truck so that the required steering angle of the machine is 20 ° or less. (1) Steer the machine gradually to the right or left.
Page 305 OPERATION MACHINE OPERATIONS AND CONTROLS Release the accelerator pedal, lower the engine speed, and depress the brake pedal to stop the machine. Change the gear speed from REVERSE 2nd to FOR- WARD 2nd by the travel direction switching operation. Drive the machine forward with steering operation so that it comes at right angles against the dump truck.
Page 306: Remote Positioner
MACHINE OPERATIONS AND CONTROLS OPERATION After finishing the loading, if the spillage of the load is pre- dicted, hold the loaded materials gently by using the buck- REVERSE TRAVEL FROM DUMP TRUCK NOTICE • Do not perform the gear shift operation while depressing the accelerator pedal (while the engine is running at high speed).
Page 307 OPERATION MACHINE OPERATIONS AND CONTROLS Set bucket control lever (2) to “DUMP” position (c) to dump the bucket. Set bucket control lever (2) to “detent” position (d), and re- lease bucket control lever (2). Bucket control lever (2) stops in that position. The bucket tilts and stops at the setting position of the re- mote bucket positioner.
Page 308 MACHINE OPERATIONS AND CONTROLS OPERATION (The bucket stop angle is a rough indication.) METHOD FOR RELEASING REMOTE BUCKET POSITIONER If you want to release the bucket stop position setting, perform the following operations. Keep pressing (b) of remote positioner switch (3) for 1 second or longer.
Page 309 OPERATION MACHINE OPERATIONS AND CONTROLS Remote positioner LOWER pilot lamp It lights up in green only in boom LOWER operation when the remote positioner is effective. Remote positioner RAISE/LOWER pilot lamp It lights up in green in both of boom RAISE and LOWER opera- tions when the remote positioner is effective.
Page 310 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR SETTING RAISE REMOTE BOOM POSITIONER Operate boom control lever (1) and place the boom height above the horizontal level, then return boom control lever (1) to “HOLD” position. Press (a) of remote positioner switch (2). The buzzer “beeps in a short duplet”, and the boom raise stop position is set.
Page 311: Method For Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS REMARK If the boom control lever is at near the set position of boom lower stop (approximately within 2 °), the lever cannot be set to “FLOAT” position. METHOD FOR RELEASING LOWER REMOTE BOOM POSITIONER When the boom is above the horizontal level, the boom RAISE stop position setting can be made. And when the boom is below the horizontal level, the boom LOWER stop position setting can be made.
Page 312 Stop the machine, and then apply the parking brake. If the parking brake was used as a secondary brake when the machine was traveling, ask your Komatsu distributor for inspection of the parking brake system. Release accelerator pedal (1), then depress R.H. brake pedal (2) to stop the machine.
Page 313 OPERATION MACHINE OPERATIONS AND CONTROLS Release R.H. brake pedal (2) gradually. Operate work equipment control levers (6) and (7), and lower the bucket to the ground. Set bucket control lever (6) to “HOLD” position (c). Set boom control lever (7) to “HOLD” position (b). Press (a) of work equipment lock switch (8) and lock the work equipment.
Page 314: 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 315 OPERATION MACHINE OPERATIONS AND CONTROLS (1) Cab door (2) Radiator reservoir tank coolant filler cap (3) Radiator guard side cover (2 places) (4) Engine side cover (2 places) (5) Download connector cover (1) Transmission oil tank filler cap (7) Filler port cover for fuel tank and DEF tank (8) Air cleaner inspection cover (9) Hydraulic tank oil filler cap The starting switch key is a common key for (1) to (9).
Page 316 MACHINE OPERATIONS AND CONTROLS OPERATION PROCEDURES FOR LOCKING HYDRAULIC OIL FILLER PORT CAP Screw in the oil filler cap. Insert the starting switch key into the key slot. Turn the starting switch key to “LOCK” position (B), and then align the key slot with the match mark (1) of the cap. Position (A) OPEN Position (B)
Page 317 OPERATION MACHINE OPERATIONS AND CONTROLS Insert the starting switch key into the key slot. Turn the starting switch key to “LOCK” position (B), and then align the key slot with the match mark (1) of the cap. Position (A) OPEN Position (B) LOCK Remove the starting switch key.
Page 318 MACHINE OPERATIONS AND CONTROLS OPERATION Insert the starting switch key into the key slot. Turn the starting switch key to “LOCK” position (B), and then align the key slot with match mark (1) of the cap. Position (A) OPEN Position (B) LOCK Remove the starting switch key.
Page 319: Method For Removing Bucket
OPERATION MACHINE OPERATIONS AND CONTROLS Pull cab door knob (2). By pulling knob (2) of the cab door, it opens to OPEN posi- tion of stopper (4) by gas spring (3). REMARK To open the cab door from inside, pull the cab door open knob.
Page 320 If the boom length is not suitable for the bucket capacity, the machine loses the balance and may tip over. For details of the combination of the bucket and boom, consult your Komatsu distributor. NOTICE Apply this method of removal and installation to the standard specification machine.
Page 321 OPERATION MACHINE OPERATIONS AND CONTROLS Remove mounting bolt (4). 10. Remove the right and left bucket hinge pins (5). 11. Remove the chocks from the tires, and start the engine. 12. Drive the machine in reverse, and separate bucket (7) from boom (6).
Page 322 MACHINE OPERATIONS AND CONTROLS OPERATION Operate the work equipment control lever to align the right and left pin holes of the bucket with those of the boom. Select the number of shims so that clearance (a) between bucket hinge boss (4) and boom boss (1) is 1.5 mm or less on each side.
Page 323: 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. •...
Page 324 MACHINE OPERATIONS AND CONTROLS OPERATION Deflection ratio = (H − h) / H x100 As a guideline that can be checked visibly, the deflection ratio of the front tire (deflection/free height) is as follows. When carrying normal load (boom horizontal): Approximately 15 to 25 % When digging (rear wheels off ground): Approximately 25 to 35 %...
Page 325 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. PRECAUTIONS FOR STONE HANDLING OPERATION When performing the stone handling work, select proper tires corresponding to the working condition.
Page 326 MACHINE OPERATIONS AND CONTROLS OPERATION Installa- Applying ballast (*2) Simultaneous use of tion of mesh chain and bal- Specification mesh last chain (*1) Standard specification + additional counterweight ○ Machine with load-and-carry specification ○ ○ Machine with logging specification *1: Mesh chain can be installed to all 4 wheels. *2: Ballast can be applied to rear wheels only.
Page 327: 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 328: 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) Air conditioner display (5) Temperature control switch Air conditioner display (A) Air flow bar (E) Vent display...
Page 329 OPERATION HANDLE AIR CONDITIONER FAN SWITCH You can adjust the air flow by using the fan switch. The air flow can be adjusted to 6 levels. Press the △ switch to increase the air flow; press the ▽ • switch to decrease the air flow. •...
Page 330 HANDLE AIR CONDITIONER OPERATION REMARK If the mode is set to automatic operation and the temperature setting is set to 18 °C or 32 °C, the air flow from the fan is always set to “HIGH” and does not change even when the temperature reaches the set temperature. VENT SELECTOR SWITCH In the manual operation, use the vent selector switch to select the vents.
Page 331 OPERATION HANDLE AIR CONDITIONER Vent Liquid crystal dis- Air vent mode Remarks play This is not selectable during the automatic operation Defroster vent ○ (This can be selected only when the defroster switch is pressed.) Air blows out from the vents marked with ○. AUTO SWITCH Auto switch is used to switch the operation to the automatic op- eration.
Page 332 HANDLE AIR CONDITIONER OPERATION FRESH Outside air is taken into the cab. Use this setting to take in fresh air or to demist the window glass. REMARK Intake of external air (FRESH) is automatically selected when the cab door is opened. Selection by use of the FRESH/RECIRC air selector switch is not available.
Page 333: 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, the automatic operation symbol on the air condi- tioner display goes out and the defroster mark is dis- played.
Page 334 HANDLE AIR CONDITIONER OPERATION The automatic operation symbol on the air conditioner dis- play lights up. Press switch △ or switch ▽ 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 environ- ment, and the air conditioner is operated automatically to provide the set temperature.
Page 335 OPERATION HANDLE AIR CONDITIONER METHOD FOR MANUAL OPERATION Press switch △ or switch ▽ of the fan switch and adjust the air flow. If switch △ of the fan switch is pressed while the air condi- tioner power supply is turned off, the air conditioner power supply is turned on and the air flow is set to “Low”.
Page 336 HANDLE AIR CONDITIONER OPERATION Press the FRESH/RECIRC air selector switch and select the recirculation of the air inside the cab (RECIRC) or the intake of fresh air from outside (FRESH). REMARK To select the automatic operation during manual operation, press AUTO switch. METHOD FOR STOPPING MANUAL OPERATION Press the air conditioner OFF switch.
Page 337 OPERATION HANDLE AIR CONDITIONER Press switch △ of the temperature control switch and set the temperature to 32.0 °C. To remove frost quickly, press switch △ of the fan switch and set the air flow to “Hi”. METHOD FOR OPERATING DEMIST Dew condensation adhered to the inside of the window glass can be removed by demist operation.
Page 338: Handle Radio
HANDLE RADIO OPERATION HANDLE RADIO • To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to failure. Take care not to let water get on them.
Page 339 OPERATION HANDLE RADIO PRESET BUTTON If you register desired stations to the preset button beforehand, you can select each station by touching this but- ton once. It is possible to preset 6 stations each for both AM and FM. For the presetting method, see “METHOD FOR CONTROLLING RADIO (3-272)”. DISPLAY SELECTOR BUTTON Use the display selector button to change frequency and clock shown on the display.
Page 340: Method For Controlling Radio
HANDLE RADIO OPERATION Press the band/AUX selector button and select AUX. METHOD FOR CONTROLLING RADIO METHOD FOR ADJUSTING FREQUENCY Press band/AUX selector button (1) and select FM or AM. Press tuning/time adjustment button (2) to adjust the fre- quency. Press the △ button, and the frequency increases; •...
Page 341 OPERATION HANDLE RADIO METHOD FOR REGISTERING PRESET Hold down one of 1 to 6 of preset button (1) while listening to the radio. The currently received frequency is registered to the preset number corresponding to the pressed button. “Example” While a frequency is displayed, keep pressing button 1 of pre- set button (1), and the preset number “P-1”...
Page 342 HANDLE RADIO OPERATION METHOD FOR ADJUSTING CLOCK Press display selector button (1) to display the time. Hold down display selector button (1) to flash the “HOUR” display portion. You can adjust the hour. Press tuning/time adjustment button (2) to adjust the hour. If you press △...
Page 343: Transportation
WARNING This machine may need to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. METHOD FOR SECURING MACHINE Set chocks at the front and rear of the tires to prevent the machine from moving.
Page 344: Method For Lifting Machine
This method of lifting applies to the standard specification machine. The method of lifting differs depending on the attachments and options installed. For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor. For the weight, see “SPECIFICATIONS (5-2)”.
Page 345: Precautions For Disassembling And Assembling Work Equipment
OPERATION TRANSPORTATION Set the frame lock bar to LOCK position (L) to lock the front and rear frames. 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.
Page 346: Cold Weather Operation
If DEF or the machine installed with DEF cannot be stored in the indoors where the temperature is at -11 °C or higher (if they are left outdoors in cold weather), the DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF, and keep it in the condition free from freezing. •...
Page 347: Precautions After Daily Work Completion
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 348 COLD WEATHER OPERATION OPERATION 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. 3-280...
Page 349: 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. Perform the following items when using the machine after long-term storage. • Wipe off the grease from the piston rods of the hydraulic cylinder.
Page 350 If SCR system has any abnormality, stop the engine, and then start it again. If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If the DEF is kept in the DEF tank for more than 1 year, replace it.
Page 351: Troubles And Actions
Do not tow any load greater than this. • For details of 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 352 TROUBLES AND ACTIONS OPERATION • Keep the angle of the towing rope as small as possible. Keep the angle between the center lines of the 2 machines to within 30 °. • Usually, use a towing machine of the same class as the machine being towed. Check that both towing ma- chine and towed machine have ample braking power, and rim pull to allow them to control both machines on slopes or on the tow road.
Page 353 OPERATION TROUBLES AND ACTIONS METHOD FOR RELEASING PARKING BRAKE WITH SECONDARY PARKING BRAKE RELEASE SWITCH If the caution lamp for the parking brake is not lit when the pressure in the brake accumulator is high and the starting switch is turned to ON position, release the parking brake according to the following procedure. Turn the starting switch to ON position (B).
Page 354 The normal gear shifting operation is performed by electric signals. 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. 3-286...
Page 355: Precautions For Discharged Battery
OPERATION TROUBLES AND ACTIONS 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 to OFF positions.
Page 356 TROUBLES AND ACTIONS OPERATION REMARK The battery is at the rear left of the machine. 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 (3-287)”...
Page 357 OPERATION TROUBLES AND ACTIONS NOTICE • The starting system for this machine uses 24 V. Accordingly, the normal machine must be equipped with a 24 V power supply. • The sizes of the jumper cables and clips should be suitable for the battery size. •...
Page 358 TROUBLES AND ACTIONS OPERATION Remove the clip of jumper cable (B) from engine block (E) on the failed machine. Remove the clip of jumper cable (B) from the negative (-) terminal of battery (D) on the normal machine. Remove the clip of jumper cable (A) from the positive (+) terminal of battery (D) on the normal machine.
Page 359: Method For Lowering Work Equipment When Stopping Engine
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 360 PHENOMENA AND ACTIONS FOR CHASSIS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 361 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Machine moves slowly and lacks Lack of oil in transmission case Add oil to specified level. For details, power even with engine running at see WHEN REQUIRED. full throttle. Clogged screen Disassemble and clean. (*) Oil overheats.
Page 362 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 363 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Engine coolant temperature caution Clean or repair them. For details, see Clogged radiator fins or damaged fin lamp lights up. WHEN REQUIRED. Defective thermostat Replace thermostat. (*) Defective sealing of thermostat Replace thermostat seal. (*) Loose radiator filler cap Tighten cap or replace packing.
Page 364 “CA559” is displayed on “Current Abnormality” screen, re- place both fuel main filter and fuel prefilter immediately. If “CA2249” or “CA559” is not cleared even after the re- placement, ask your Komatsu distributor for inspection im- mediately, even though the machine can perform normal operation.
Page 365 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. 3-297...
Page 367: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 368: 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 369: Precautions For Scr Assembly
MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR SCR ASSEMBLY Be careful for the high temperature parts when performing inspection and maintenance. Even after the engine stops the parts around SCR device may be at high temperature. DUSTY JOBSITES When working at dusty jobsites, observe the following. •...
Page 370: Close Engine Side Cover Securely
PRECAUTIONS FOR MAINTENANCE MAINTENANCE 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 371: Outline Of Maintenance
• When using commercially available oil, it may be necessary to reduce the oil change interval. We recom- mend that you use the Komatsu oil clinic to check the characteristics of the oil in detail. NOTICE Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu...
Page 372 (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 373 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 374 Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor. STORE OIL AND FUEL • Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
Page 375: Handle Electrical Components
Install the electrical components of devices that are 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. •...
Page 376: 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 377 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Taper seal Width Tightening torque Outside di- acros ameter of Target value Allowable range s flats hose “a” “b” (mm) (mm) 34 to 63 3.5 to 6.5 59 to 98 6.0 to 10.0 10.5 84 to 132 8.5 to 13.5...
Page 378: Maintenance Schedule
250 hours. For details, see the oil part number and note in “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-5)”. • Contact your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 50 HOURS) ..........4-14 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ..........
Page 379 MAINTENANCE MAINTENANCE SCHEDULE TABLE METHOD FOR LUBRICATING CENTER HINGE PIN ................4-64 METHOD FOR LUBRICATING DRIVE SHAFT CENTER SUPPORT............4-65 METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS....4-66 METHOD FOR CHECKING AND LUBRICATING DRIVE BELT TENSION PULLEY ASSEMBLY OF COM- PRESSOR FOR ALTERNATOR AND AIR CONDITIONER ..............
Page 380: Maintenance Procedure
MAINTENANCE PROCEDURE MAINTENANCE MAINTENANCE PROCEDURE INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 50 HOURS) Until the first 50 hours operation, perform the following maintenance every 10 hours. • Lubrication of work equipment • Lubrication of steering cylinder For details of the method of replacement or maintenance, see EVERY 100 HOURS MAINTENANCE. INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) Perform the following maintenance work only after the first 250 hours of operation on new machines.
Page 381 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING AIR CLEANER NOTICE The electric air cleaner clogging sensor and dust indicator are used to indicate clogging on the air cleaner. The electric air cleaner clogging sensor indicates the cleaning timing of the air cleaner element and the dust indicator indicates the level of clogging.
Page 382 MAINTENANCE PROCEDURE MAINTENANCE Open inspection cover (1) of air cleaner on the right side of machine, and lock it. Remove clips (2) (6 places) and remove cover (3). Hold the outer element (4), rock it lightly up and down and to the right and left, and pull the outer element (4) out while turning it to the right or left.
Page 383 MAINTENANCE MAINTENANCE PROCEDURE 10. Blow dry compressed air (Max. 0.2 MPa {2.1 kg/cm }) from the inside of the outer element along the pleats. 11. Blow along the pleats from the outside, then blow again from the inside. 12. After cleaning the outer element, illuminate the inside of the element with an electric bulb to check.
Page 384 MAINTENANCE PROCEDURE MAINTENANCE 19. Press the button of the dust indicator and return the yellow piston. If the air cleaner clogging caution lamp lights up or the yel- low piston reaches the red line (7.5 kPa {0.076 kg/cm immediately after the cleaning of the outer element, re- place the inner and outer elements with new ones.
Page 385 MAINTENANCE MAINTENANCE PROCEDURE If any dust is attached to vacuator valve (7) installed to cover (3), remove it. Check that the lip of vacuator valve (7) has no crack. If there is any crack, replace it with a new one. Remove inner element (5), and then quickly install the new inner element.
Page 386: 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 387 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 388 MAINTENANCE PROCEDURE MAINTENANCE Check that the coolant temperature is low enough to make it possible to touch the radiator cap surface by bare hand, turn radiator cap (2) slowly until it hits the stopper, and re- lease the pressure. Then, while pushing radiator cap (2), turn it until it touches the stopper, and remove it.
Page 389: Method For Checking Oil Level In Transmission Case, Adding Oil
MAINTENANCE MAINTENANCE PROCEDURE 16. Drain the coolant in reservoir tank (6). 17. Clean the inside of reservoir tank. 18. Add Non-Amine Engine Coolant (AF-NAC) to the middle between FULL and LOW. 19. Stop the engine. 20. Approximately 3 minutes later, add Non-Amine Engine Coolant (AF-NAC) up to the mouth of the coolant filler port.
Page 390 MAINTENANCE PROCEDURE MAINTENANCE Add oil through oil filler port (F) if it is not within range (A) at upper part of sight gauge (G). Remove drain plug (1), install the nipple, and attach the hose to it if it exceeds range (A) at upper part of sight gauge (G).
Page 391: Method For Checking Oil Level In Axle Case And Adding Oil
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING OIL LEVEL IN AXLE CASE AND ADDING OIL WARNING • When checking the oil level, apply the parking brake and fix the front and rear frames using the frame lock bar. • Immediately after the engine is stopped, parts and oil are still very hot. Wait for the temperature to go down, and then start the work.
Page 392: Method For Cleaning Axle Breather
MAINTENANCE PROCEDURE MAINTENANCE Remove the plug (1) or level plug (2), and check the oil level. Figure A shows the front axle, and B shows the rear axle. If the oil is close to the lower edge of the hole of the plug, the oil level is correct.
Page 393: Method For Cleaning Air Conditioner Condenser
MAINTENANCE MAINTENANCE PROCEDURE Remove mud and dust around the breather by using a brush, etc. Figure A shows the front axle, and B shows the rear axle. Remove the breather, immerse it in detergent liquid, and clean it. • Clean the breathers in 2 locations, the front and rear sides.
Page 394: Method For Cleaning Radiator Fin And Cooler Fin
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING RADIATOR FIN AND COOLER FIN WARNING • If compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by the compressed air, high-pressure water, or steam, there is a danger of personal injury. Always wear protective equipment such as protective eyeglasses and dust mask.
Page 395 MAINTENANCE MAINTENANCE PROCEDURE Select “Fan Reverse Mode” on “Machine Setting and Infor- mation” menu screen, then press ENTER switch (1). Press ENTER switch (1) to rotate the fan in the reverse di- rection. If the fan reverse operation is performed without satisfying the condition for reversing the fan, the screen shown in the figure is displayed, and the fan rotation direction cannot be switched.
Page 396: Method For Cleaning Fin With Compressed Air
MAINTENANCE PROCEDURE MAINTENANCE REMARK If many of twigs, wood chips, etc. are stuck, open the side cove (3) of radiator guard and run the engine at high idle. The twigs and wood chips are discharged through opening area of the side cover. For safety, check that no person is around, and then per- form the cleaning since the discharged twigs and wood chips will be scattered around.
Page 397 MAINTENANCE MAINTENANCE PROCEDURE Set the parking brake switch to ON position (operate). Stop the engine. Remove the bolts (1), open radiator grille (2) and fix it with the bar. Remove the bolts (4) of fan nets (3), and remove the fan nets.
Page 398: Method For Replacing Bucket Teeth
MAINTENANCE PROCEDURE MAINTENANCE Open radiator guard side covers (9) on the right and left side of machine, and fix them with the rod. 10. Blow the dust off from the front and rear of radiator fin (8). 11. Check the rubber hoses. If any hose is cracked or hard- ened by age, replace with a new one.
Page 399 Remove the tooth (2). REMARK If it cannot be removed by this method, ask your Komatsu distributor to have the replacement performed for safety. Clean bucket adapter (3) thoroughly. Install a new bucket tooth to bucket adapter (3).
Page 400 MAINTENANCE PROCEDURE MAINTENANCE Push out the pin (1) to the direction of arrow by hand or hammer, and remove the tooth (2). Check the torque to unlock the pin by using torque wrench according to the following procedure. Rotate the shaft of pin (1) with the torque wrench, and set it to the lock state (90 °).
Page 401: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE MAINTENANCE PROCEDURE Raise the bucket to a suitable height, then put a block (A) under the bucket to prevent the bucket from lowering. Set the bottom of bucket to be level, and put a block under the bucket at the center. Lower the bucket on the block and stabilize it.
Page 402: Method For Bleeding Air From Hydraulic Circuit
(b) in the figure shows that the refrigerant gas is insuffi- cient state when seeing the condition through sight glass. Ask your Komatsu distributor for refilling with the refriger- ant gas. A: Quantity of refrigerant...
Page 403 MAINTENANCE MAINTENANCE PROCEDURE For the details, consult your Komatsu distributor. METHOD FOR BLEEDING AIR FROM PISTON PUMP NOTICE Bleed the air completely. Otherwise, it may damage the piston pump. Before bleeding the air from the piston pump, check that the hydraulic tank is filled with hydraulic oil to the upper end of sight gauge.
Page 404: Method For Bleeding Air From Fuel Circuit
MAINTENANCE PROCEDURE MAINTENANCE Set the parking brake switch to ON position (operate). Run the engine at low idle for approximately 5 minutes, and check each part for oil leakage. Bleed air from the steering cylinder according to the following procedure. Run the engine at low idle, and operate the steering cylinder to around the stroke end 4 to 5 times.
Page 405 MAINTENANCE MAINTENANCE PROCEDURE For the machine with rear fender, operate lever (a) downward, and open cover (b) before the work. Turn the starting switch to OFF position (A). Open engine side cover (1) on the right side of machine, and fix it with the rod and band. Tilt switch for the fuel feed pump (2) to ON position.
Page 406: Method For Checking Function Of Ecss Accumulator
If there is no change in the vertical motion between the 2 settings, the accumulator gas pressure has proba- bly dropped. Ask your Komatsu distributor for inspection. REMARK The inspection must be performed with the gear speed of the 2nd to the 4th, and with the travel speed of 5 km/h or faster.
Page 407 Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the tires shown in the following table. The travel speed displayed varies with the tire size. Contact your Komatsu distributor when installing the optional tire. Maximum load (kg) Tire size...
Page 408: Checks Before Starting
MAINTENANCE PROCEDURE MAINTENANCE Tire size Standard inflation pressure Front wheel:525 kPa {5.4 kg/cm 35/65-33-36PR (standard) Rear wheel:525 kPa {5.4 kg/cm Front wheel:625 kPa {6.4 kg/cm 35/65-33-42PR (if equipped) Rear wheel:625 kPa {6.4 kg/cm Front wheel:590 kPa {6.0 kg/cm 35/65R33☆ (if equipped) Rear wheel:490 kPa {5.0 kg/cm Front wheel:750 kPa {7.6 kg/cm 35/65R33☆☆ (if equipped) Rear wheel:650 kPa {6.6 kg/cm NOTICE Appropriate inflation pressure varies depending on the given type of work.
Page 409: Every 50 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE • Check water separator, drain water and sediment • Check coolant level, add coolant • Check oil level in engine oil pan, add oil • Check dust indicator • Check electric wiring • Check fuel level, add fuel •...
Page 410 MAINTENANCE PROCEDURE MAINTENANCE For applying grease to dump cylinder pin (2), bell crank pin (3), bucket link pin (4), bucket hinge pin (5), and lift cylinder pin (6), the bucket should be lowered to the ground with the bucket on the level.
Page 411: Method For Lubricating Steering Cylinder
MAINTENANCE MAINTENANCE PROCEDURE (1) Boom pivot pin (2 places) (2) Dump cylinder pin (2 places) (6) Lift cylinder pin (4 places) (2) Dump cylinder pin (2 places) (3) Bell crank pin (1 place) (4) Bucket link pin (2 places) (5) Bucket hinge pin (2 places) (6) Lift cylinder pin (4 places) METHOD FOR LUBRICATING STEERING CYLINDER (4 places)
Page 412: Method For Lubricating Rear Axle Pivot Pin
MAINTENANCE PROCEDURE MAINTENANCE Set the frame lock bar to LOCK position (L). By using a grease pump, pump in grease through the grease fitting shown by arrow. After greasing, wipe off any old grease that is pushed out. (1) Steering cylinder bottom end (2 places) (2) Steering cylinder rod end (right) (3) Steering cylinder rod end (left) METHOD FOR LUBRICATING REAR AXLE PIVOT PIN...
Page 413: Method For Checking Oil Level In Hydraulic Tank, Adding Oil
MAINTENANCE MAINTENANCE PROCEDURE By using a grease pump, pump in grease through the grease fitting shown by arrow. After greasing, wipe off any old grease that is pushed out. METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL WARNING •...
Page 414: Every 250 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING AIR CONDITIONER FRESH AIR FILTER WARNING When using compressed air, there is a danger that dirt may scatter and cause personal injury. Always wear protective equipment such as protective eyeglasses and dust mask. When the air conditioner is used, clean the air conditioner fresh air filter. Before cleaning the filter, stop the air conditioner.
Page 415 Neutralize the removed fluid with baking soda (sodium bi- carbonate), then flush it away with a large amount of wa- ter. If necessary, consult your Komatsu distributor or a bat- tery manufacturer. Release the lock of battery box cover (1), and close the cover.
Page 416: Method For Testing Parking Brake
(sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer. Release the lock of battery box cover (1), and close the cover.
Page 417: Method For Cleaning Air Conditioner Recirc Air Filter
• 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. 4-51...
Page 418: Every 500 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE REMARK The inspection must be done within 5 minutes after the engine stops. If the engine is kept stopped, the gas pressure in the accumulator lowers and the inspection cannot be made. EVERY 500 HOURS MAINTENANCE Maintenance for every 50, 100 and 250 hours should be performed at the same time. METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGE WARNING...
Page 419 Install the hose to oil drained port of drain plug (P), and loosen drain plug (P) to drain the oil. Check the drained oil. If it contains much metallic powder or foreign material, contact your Komatsu distributor. REMARK Use the attached hose to prevent the oil from splashing around.
Page 420: 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 421 MAINTENANCE MAINTENANCE PROCEDURE Place a container under the fuel prefilter cartridge (2) to catch the fuel. Loosen drain valve (3) and drain water and sediments from transparent cup (4), and also drain all the fuel from fil- ter cartridge (2). Remove the drain hose (5).
Page 422: Method For Replacing Fuel Main Filter 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 423: Method For Replacing Transmission Oil Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE Place a container under the filter cartridge (2) to catch the fuel. Turn the filter cartridge (2) counterclockwise by using the filter wrench, and remove it. Clean the filter head. Coat the packing surface of the new filter cartridge with oil. Install the new filter cartridge to the filter head.
Page 424: Method For Checking And Replacing Alternator And Air Conditioner Compressor Drive Belt
MAINTENANCE PROCEDURE MAINTENANCE Loosen the bolts (1) (6 pieces) under the component box, and open the cover (2). Place a container under the transmission filter (3) to catch the drained oil. Remove the transmission filter plug (4) and drain the oil. After draining the oil, tighten the plug (4).
Page 425 MAINTENANCE MAINTENANCE PROCEDURE Open radiator guard side cover (1) on the right side of ma- chine, and fix it with the rod. Remove bolts (2), and remove bulkhead covers (3) and (4) which separate the engine compartment and radiator com- partment.
Page 426 MAINTENANCE PROCEDURE MAINTENANCE Open engine side cover (1) on the right side of machine, and fix it with the rod and band. Loosen locknut (3) of push bolt (2), tighten push bolt (2) fully, and press tension pulley (4). Belt (5) becomes loose. Open radiator guard side cover (6) on the right side of ma- chine, and fix it with the rod.
Page 427: Method For Replacing Brake Oil Filter Cartridge
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING BRAKE OIL FILTER CARTRIDGE (Only for the machine with brake cooling system) WARNING Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury. Wait for the temperature to go down, and then start the work. Items to be prepared •...
Page 428: Every 1000 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE EVERY 1000 HOURS MAINTENANCE Maintenance for every 50, 100, 250 and 500 hours service should be performed at the same time. METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT WARNING Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury. Wait for the temperature to go down, and then start the work.
Page 429 MAINTENANCE MAINTENANCE PROCEDURE For the machine equipped with the undercover, remove the cover at opening section of undercover, change the oil, and clean the strainer. Set the frame lock bar to LOCK position (L). Place a container under the drain plug (1) to catch the drained oil.
Page 430: Method For Cleaning Transmission Breather
MAINTENANCE PROCEDURE MAINTENANCE 11. Take out the strainer (6). 12. Remove the dirt from strainer (6), then wash it in the clean diesel fuel or flushing oil. If the strainer (6) is damaged, replace it with a new one. 13. Install the strainer (6) to the case. Replace the O-ring (7) on the strainer with a new one.
Page 431: Method For Lubricating Drive Shaft Center Support
MAINTENANCE MAINTENANCE PROCEDURE Set the frame lock bar to LOCK position (L). By using a grease pump, pump in grease through the grease fitting shown by arrow. After greasing, wipe off any old grease that is pushed out. METHOD FOR LUBRICATING DRIVE SHAFT CENTER SUPPORT (1 place) Set the frame lock bar to LOCK position (L).
Page 432: Method For Checking All Tightening Points Of Engine Intake Pipe Clamps
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 LUBRICATING DRIVE BELT TENSION PULLEY...
Page 433: Every 2000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE For the machine with rear fender, operate lever (a) downward, and open cover (b) before the work. Open engine side cover (1) on the right side of machine, and fix it with the rod and band. By using a grease pump, pump in grease through the grease fitting shown by arrow.
Page 434 MAINTENANCE PROCEDURE MAINTENANCE Stop the engine. Open cover (1) at the right side of cab, and fix it with the bar. Remove the cap of oil filler port (F) and plug (2) of the filter case. Place a container under drain plug (3) to catch the drained oil.
Page 435 MAINTENANCE MAINTENANCE PROCEDURE 17. Remove the bolts (11) (4 pieces) and remove cover (12). 18. Pull out strainer (15) together with rod (13) and spring (14). 19. Remove any dirt stuck to strainer (15), then wash it in flushing oil. If strainer (15) is damaged, replace it with a new one.
Page 436: Method For Replacing Hydraulic Tank Breather Element
MAINTENANCE PROCEDURE MAINTENANCE Check that it is at the specified level. For details, see “METHOD FOR CHECKING OIL LEVEL IN HY- DRAULIC TANK, ADDING OIL (4-47)”. 35. Check the filter cover mount for oil leakage. 36. Release the lock of cover (1), then close the cover. METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT WARNING •...
Page 437 MAINTENANCE MAINTENANCE PROCEDURE REMARK When the given work requires to use the brake more frequently than usual, replace the axle oil earlier than the usual timing. Refill capacity Front: 185 ℓ Rear: 195 ℓ Items to be prepared Container to catch the drained oil Perform the following in order to prevent the drained oil from coming in contact with tires.
Page 438: Method For Replacing Air Conditioner Fresh/Recirc Air Filters
Wait for the temperature to go down, and then start the work. For details of air bleeding from hydraulic circuit, consult your Komatsu distributor. Set the bottom of bucket to be level, and lower the work equipment to the ground.
Page 439: Method For Cleaning Work Equipment Circuit Strainer
Wait for the temperature to go down, and then start the work. For details of air bleeding from hydraulic circuit, consult your Komatsu distributor. Set the bottom of bucket to be level, and lower the work equipment to the ground.
Page 440: Method For Cleaning Steering Circuit Strainer
Wait for the temperature to go down, and then start the work. For details of air bleeding from hydraulic circuit, consult your Komatsu distributor. Set the bottom of bucket to be level, and lower the work equipment to the ground.
Page 441: Method For Checking Function Of Ppc Accumulator
MAINTENANCE MAINTENANCE PROCEDURE Remove the hose connected to strainer block (2) of steer- ing circuit, and remove strainer block (2) of steering circuit from steering pump. Remove the cap (3) of strainer block (2), and remove the strainer (4). Clean the strainer (4) in clean diesel oil. Install the strainer (4) to strainer block (2), and install the cap (3).
Page 442: Method For Checking Alternator
Replace the accumulator for every 4000 hours or every 2 years whichever comes sooner. METHOD FOR CHECKING ALTERNATOR Ask your Komatsu distributor for check of the alternator every 2000 hours or every 1 year, whichever comes sooner. METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance.
Page 443 MAINTENANCE MAINTENANCE PROCEDURE Set the bottom of bucket to be level, and lower the work equipment to the ground. Set the parking brake switch to ON position (operate). Stop the engine. Wait for the temperature of each part to drop. Place a container under the upper plug (1) of the work equipment pin to catch the drained oil.
Page 444: 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 445 MAINTENANCE MAINTENANCE PROCEDURE The KCCV ventilator is located in the positions shown in the figure. For the use of the special wrench, see the figure. For the machine with rear fender, operate lever (a) downward, and open cover (b) before the work. Open the engine side cover on the right side of machine, and fix it with the rod and band.
Page 446 MAINTENANCE PROCEDURE MAINTENANCE After 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 447: 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 448 MAINTENANCE PROCEDURE MAINTENANCE After the engine is stopped, the devices are still operated for a few minutes. Before replacing the filter, clean around the DEF pump first after the DEF system devices stop. Items to be prepared • DEF filter removal tool •...
Page 449 MAINTENANCE MAINTENANCE PROCEDURE Insert the filter removal tool (3) into the bottom of the DEF pump and thrust in by hand. Check that the filter removal tool (3) is fully inserted to the end. Insert the filter removal tool (3) to the end where you can- not thrust it in any further.
Page 450: Method For Replacing Def Tank Breather Element
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 451: Every 4000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Open engine side cover (1) on the right side of machine, and fix it with the rod and band. Remove the nut (3) of breather assembly (2), and then re- move cover (4). Replace breather (5) with a new one. Install the cover (4) and nut (3).
Page 452: Method For Lubricating Drive Shaft
Transmission 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. Main pump LS hose Hydraulic drive fan hose (Exhaust fan) External work equipment hose Lift cylinder hose •...
Page 453: Method For Checking Water Pump
(4) Upper drive shaft (2 places) METHOD FOR CHECKING WATER PUMP Check for leakage of water and oil around the water pump. If any problem is found, ask your Komatsu distributor to perform disassembly, repair, or replacement. METHOD FOR CHECKING STARTING MOTOR Ask your Komatsu distributor to have the starting motor checked.
Page 454 MAINTENANCE PROCEDURE MAINTENANCE If there is any problem, the related parts must be replaced. Ask your Komatsu distributor for replacement. METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER The fuel spray prevention cap acts to prevent the fuel from coming into contact with high-temperature parts of the engine and causing a fire if the fuel should leak or spray out.
Page 455: Every 4500 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE If there is any problem, the related parts must be replaced. Ask your Komatsu distributor for replacement. EVERY 4500 HOURS MAINTENANCE Maintenance for every 50, 100, 250 and 500 hours service should be performed at the same time.
Page 456: Every 9000 Hours Maintenance
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP ON FUEL DOSER PIPING Ask your Komatsu distributor for replacement of the fuel spray prevention cap on fuel doser. END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. 4-90...
Page 457: Specifications
SPECIFICATIONS...
Page 458: Specifications: Wa600-8
kg 56070 Normal load kg 11680 Bucket capacity (with spade nose m tooth) Engine model KOMATSU SAA6D125E-7 diesel engine Rated horsepower SAE J1995 (gross) • 396 / 1800 • ISO 14396 kW/ min 396 / 1800 ISO 9249 /SAE J1349 (net) 395 / 1800 •...
Page 459 SPECIFICATIONS SPECIFICATIONS WA600-8 Item Unit (in POWER mode) Ambient temperature working range °C -20 thru 45 for operation and storage *1: Value when bucket dump angle is 45 °. *2: Value when articulate angle is 43 °.
Page 460 Operating weight kg 55230 Normal load kg 12600 Bucket capacity (with spade nose m tooth) Engine model KOMATSU SAA6D125E-7 diesel engine Rated horsepower SAE J1995 (gross) • 396 / 1800 ISO 14396 • kW/ min 396 / 1800 • ISO 9249 /SAE J1349 (net)
Page 461 SPECIFICATIONS SPECIFICATIONS...
Page 463: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 464: Bucket And Tire Selection
5790 kg fication Tire selection The speed display varies with the tire size. When installing optional tires, ask your Komatsu distributor for instal- lation. Install the tire protector (mesh chain) in the site with many large boulders and sharp rocks. Check the chain for cut and sag before starting the work.
Page 465: Handle Steering Wheel Spec Machine
ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE HANDLE STEERING WHEEL SPEC MACHINE GENERAL VIEW CONTROLS AND GAUGES NAMES...
Page 466 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS (1) Engine shutdown secondary switch (19) Room lamp switch (2) Monitor brightness selector switch (20) Room lamp 2 switch (3) Hazard lamp switch (21) Staircase lighting switch (4) Directional lever (22) Revolving lamp switch (if equipped) (4) Gear speed switch (23) Working lamp switch (5) Steering wheel...
Page 467 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE OTHER EQUIPMENT NAME Inside of cab (1) Rearview monitor (7) Lunch box tray (2) Ashtray (8) Fuse (3) 24 V power supply (9) Cool box (3) Cigarette lighter (10) Cup holder (4) 12 V power supply (11) Unlock knob for cab window (5) AUX (12) Cab door inner lock...
Page 468 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS Left side of the machine (14) Front wiper (22) Circuit breaker (15) Knob for cab door (23) Battery disconnect switch (16) Frame lock bar (24) System operating lamp (17) Rearview camera (25) Auxiliary engine starting connector (18) Towing pin (26) L.H.
Page 469: Explanation Of Components
(36) DEF filter (30) Fire extinguisher (if equipped) (37) Dust indicator (31) Rear fender (if equipped) (38) R.H. DEF injector (32) Komatsu Closed Crankcase Ventilation (hereafter (39) R.H. SCR assembly KCCV) ventilator (40) R.H. KDPF (33) DEF tank (34) DEF pump EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine.
Page 470 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS SWITCHES...
Page 471 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE (1) Engine shutdown secondary switch (15) Revolving lamp switch (if equipped) (2) Monitor brightness selector switch (16) Working lamp switch (3) Hazard lamp switch (17) Rear heated wire glass switch (4) Gear speed switch (18) Secondary parking brake release switch (5) Horn switch (19) Modulation clutch engagement switch...
Page 472 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS LAMP SWITCH The lamp switch is used to light up the headlamps, clearance lamps, tail lamps, and machine monitor. (a) OFF position The lamps go out. (b) ON position The clearance lamps, tail lamps, and machine monitor light up. (c) ON (headlamp lighting) position The clearance lamps, tail lamps, headlamps, and machine monitor light up.
Page 473 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE HORN SWITCH When you press the horn switch, the horn sounds. Horn switch is located on the steering wheel. WIPER, WINDOW WASHER SWITCH NOTICE Using the wiper when the glass is dry will scratch the glass. Spray with window washer fluid before ac- tuating the wiper.
Page 474 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS Check the gear speed with shift position display on the ma- chine monitor. Manual shift There are 4 gear speeds in forward and reverse. The gear speed can be changed by turning the gear speed switch to a desired position.
Page 475 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE REMARK • When the travel speed is 12.5 km/h or lower, if the kickdown switch is pressed, the gear speed can be shif- ted down to 1st from any gear speed of the forward or reverse travel. This function facilitates the load-and-carry operation.
Page 476 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS DIRECTIONAL LEVER The directional lever is used to switch the travel direction of the machine. (F) FORWARD position It is used to drive the machine forward. (N) NEUTRAL position The machine does not move. (R) REVERSE position It is used to drive the machine in reverse.
Page 477: Machine Operations And Controls
ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE MACHINE OPERATIONS AND CONTROLS CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR'S SEAT WARNING • When adjusting the position of the operator's seat, stop the machine in a safe place, securely press the work equipment lock switch to lock the work equip- ment, and make the work equipment lock pilot lamp light up.
Page 478 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS Raise the steering tilt lock lever to FREE position (F), and adjust the steering wheel to a desired position. The adjustable range is shown below. Vertical adjust- When 0 mm Over 0 to 40 mm ment Tilt adjustment 0 to 129 mm...
Page 479 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE Check that parking brake switch (2) is in ON position (a). Check that directional lever (3) is in NEUTRAL position (N). REMARK The engine can be started only when the directional lever is in NEUTRAL position (N).
Page 480 Check that machine monitor (7) operates as follows. NOTICE If the machine monitor does not light up, there may be a failure or wire breakage. Ask your Komatsu distribu- tor for inspection. Centralized warning lamp (8) and pilot display (9) are lit for 2 seconds and off for 1 second.
Page 481 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE REMARK In approximately a second, the rearview monitor dis- plays soft version for 5 seconds. If a password has been set, the password input screen will be displayed on the monitor screen. After inputting the password, press ENTER switch.
Page 482 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS When the maintenance time caution lamp lights up in red, press the menu switch and “Maintenance” menu screen is displayed. For “Maintenance” menu screen and the remedies, see “MAINTENANCE SCREEN SETTING (3-82)”. Maintenance time caution lamp is lit for 30 seconds.
Page 483 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE METHOD FOR STARTING ENGINE METHOD FOR STARTING ENGINE IN NORMAL 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 484 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS Engine coolant tem- Preheating time perature Variable between 0 0 to -25 °C and 45 seconds Max. -25 °C 45 seconds REMARK Usually, the engine is preheated sufficiently by the automatic preheating. If it is needed to extend the pre- heating time, turn the starting switch to preheating position (D).
Page 485 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE NOTICE • Do not accelerate the engine abruptly until it is warmed up. • Do not turn the starting motor continuously for 20 sec- onds or longer. • If the engine does not start, wait for 2 minutes or so, and then try to start the engine again.
Page 486 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS After preheating pilot lamp (2) goes out, turn starting switch (1) to START position (C). Keep the starting switch (1) at position (C) to keep running the starting motor until the engine starts. The starting motor rotates to start the engine.
Page 487 METHOD FOR RUNNING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and short- en the machine life. Be sure to run in the machine for the initial 100 hours (as indicated by the service meter).
Page 488 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS METHOD FOR ENGINE WARM-UP OPERATION WARNING If the oil temperature is low in a cold weather, the response of machine for the control of the steering wheel is slow, and the machine may move differently from the operator's intension.
Page 489 If any problem is found, perform maintenance or repair. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. REMARK The cooling fan speed varies according to the following conditions, but it is not abnormal.
Page 490 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS Turn the starting switch (1) to OFF position (A), and stop the engine. Remove the key from starting switch (1). REMARK • If the starting switch is turned to OFF position while the engine is still hot, guidance (2) may be displayed on the machine monitor.
Page 491 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE METHOD FOR MOVING MACHINE WARNING • When driving the machine, always set the frame lock bar to FREE position. If the frame lock bar is not in FREE position, the steer- ing becomes inoperative and this may lead to serious personal injury or death.
Page 492 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS Press (a) of work equipment lock switch (4) and unlock the work equipment. Make the work equipment lock pilot lamp on machine mon- itor (1) go out. Operate work equipment control levers (2) and (3) to set the work equipment to the travel posture and raise it to height (a) of 50 to 60 cm.
Page 493 It is used to drive the machine in reverse. Place directional lever (10) in REVERSE position (R), and check that the backup alarm sounds. If the backup alarm does not sound, ask your Komatsu distributor for repairs. 10. Release R.H. brake pedal (5), then depress accelerator pedal (11).
Page 494 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS Release accelerator pedal (1), then depress R.H. brake pedal (2) to stop the machine. Set directional lever (3) in NEUTRAL position (N). Set parking brake switch (4) to ON position (a), and apply the parking brake.
Page 495 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE METHOD FOR SHIFTING GEARS WARNING Avoid sudden gear shifts when traveling at high speeds. Before shifting down the gear, apply the brake to reduce the travel speed. Shift gear as follows. Check the transmission shift mode with machine monitor (1) and transmission shift mode selector switch (2).
Page 496 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS Check the gear speed with shift position display on ma- chine monitor (1). REMARK • If the gear speed switch is operated slowly or is stop- ped between gear positions, the centralized warning lamp may light up and the alarm buzzer may sound, but this is not a failure.
Page 497 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE When the machine is decelerated by releasing accelerator pedal (4), the transmission is shifted down automatically in accordance with the travel speed. When traveling in 2nd, if kickdown switch (5) is pressed, the gear is shifted down to 1st.
Page 498 It is used to drive the machine in reverse. Place directional lever (1) in REVERSE position (R), and check that the backup alarm sounds. If the backup alarm does not sound, ask your Komatsu distributor for repairs. REMARK • If you operate the directional lever slowly or stop it at mid-...
Page 499 Check that play (a) of steering wheel is 50 to 100 mm {2.0 to 3.9 in} , and that the operation of steering wheel is nor- mal. If any problem is found, ask your Komatsu distributor for inspection. Front and rear frames of this machine is articulated around the connection pin (center pin) at which the 2 frames are connect- ed with each other and the rear wheels follow the trace of the front wheels.
Page 500 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS When the machine is traveling, turn steering wheel (1) to the desired direction. The machine turns. Turn steering wheel (1) lightly as it follows the turning of ma- chine. METHOD FOR OPERATING WORK EQUIPMENT WARNING •...
Page 501 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE Check the state of work equipment lock with the work equipment lock pilot lamp on machine monitor (2). Operate the work equipment with work equipment control levers (3) and (4). • Boom control lever (3) is used to control the boom. Operate boom control lever (3) back and forth.
Page 502 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS • Bucket control lever (4) is used to operate the bucket. Operate bucket control lever (4) back and forth. (a) “TILT” position If bucket control lever (4) is pulled further from “TILT” position (a), it stops at “detent”...
Page 503 Stop the machine, and then apply the parking brake. If the parking brake was used as a secondary brake when the machine was traveling, ask your Komatsu distributor for inspection of the parking brake system. Release accelerator pedal (1), then depress R.H. brake pedal (2) to stop the machine.
Page 504 HANDLE STEERING WHEEL SPEC MACHINE ATTACHMENTS AND OPTIONS Release R.H. brake pedal (2) gradually. Operate work equipment control levers (6) and (7), and lower the bucket to the ground. Set bucket control lever (6) to “HOLD” position (c). Set boom control lever (7) to “HOLD” position (b). Press (a) of work equipment lock switch (8) and lock the work equipment.
Page 505 ATTACHMENTS AND OPTIONS HANDLE STEERING WHEEL SPEC MACHINE Check that the work equipment lock pilot lamp is lit on ma- chine monitor (5). 6-43...
Page 506: Handle Load Meter
HANDLE LOAD METER ATTACHMENTS AND OPTIONS HANDLE LOAD METER LOAD METER (1) Addition/subtraction mode (3) Indication of bucket load (2) Selecting handled material display (4) Indication of total load/remaining target load The load meter allows sorting the handled materials into 5 types, measures weight of the material loaded to the bucket, and indicates the total load or the remaining target load.
Page 507 ATTACHMENTS AND OPTIONS HANDLE LOAD METER MEASURING METHOD OF LOAD METER It is necessary to understand the measuring principle of the load meter to use it with high accuracy. And pay attention to the following points when calibrating it or use it in actual measurement. Measurement start conditions The measurement starts when the following conditions are satisfied.
Page 508 HANDLE LOAD METER ATTACHMENTS AND OPTIONS NOTES ON USING LOAD METER AT OPTIMUM ACCURACY Calibration Necessity The machine monitor has registered maps which show the relationship between lift cylinder pressure and loaded weight when the bucket is loaded with no load, 1/2 of rated load, and rated load. To use the load meter at a desirable accuracy when the machine has individual variation in performance or the bucket has been repaired, the saved maps need to be corrected in advance.
Page 509: Method For Using Load Meter
ATTACHMENTS AND OPTIONS HANDLE LOAD METER Boom operation If the boom rising speed varies during measurement, the lift cylinder pressure also varies and the accuracy of the measurement of loaded weight will be reduced. Keep the boom rising speed as constant as possible (keep the boom control lever position at constant) in a measurement range (-30 °...
Page 510 HANDLE LOAD METER ATTACHMENTS AND OPTIONS Press UP switch (2) or DOWN switch (3) to select the ma- terial to handle, and press ENTER switch (4). REMARK Handled material can be changed regardless of the addi- tion whether Addition mode or Subtraction mode is select- METHOD FOR SETTING ADDITION MODE REMARK In case the load meter is set in Addition mode, even if you stop the operation by turning the starting switch to...
Page 511 ATTACHMENTS AND OPTIONS HANDLE LOAD METER Press UP switch (2) or DOWN switch (3) to select “Addi- tion”, and press ENTER switch (4). When the display returns to the standard screen, the indi- cation changes to “+” and the Addition mode is selected. METHOD FOR USING ADDITION MODE Set the load meter to Addition mode.
Page 512 HANDLE LOAD METER ATTACHMENTS AND OPTIONS When 15 seconds have passed after start of measure- ment, the indication of bucket load is cleared and dis- played as 0.0 t. The total load indication is displayed as 5.1 t. REMARK When you tilt back the bucket fully and raise the boom higher than that in the traveling posture, the measurement of the load starts.
Page 513 ATTACHMENTS AND OPTIONS HANDLE LOAD METER When you reset the indication of total load to start the next loading work, press the load meter sub total switch. The load meter display returns to the initial state. REMARK • To reset the total load indication, hold down the load meter sub total switch for 2 seconds or more.
Page 514 HANDLE LOAD METER ATTACHMENTS AND OPTIONS Press UP switch (2) or DOWN switch (3) to select “Sub- traction”, and press ENTER switch (4). When the display returns to the standard screen, the indi- cation changes to “-” and the Subtraction mode is select- METHOD FOR SETTING TARGET LOADING AMOUNT IN SUBTRACTION MODE Press the menu switch (1) on the standard screen.
Page 515 ATTACHMENTS AND OPTIONS HANDLE LOAD METER Press UP switch (2) or DOWN switch (3) to change the nu- merical number highlighted, and press ENTER switch (4). Each time you press ENTER switch (4), the next entry starts. When the last digit is highlighted and you press EN- TER switch (4), the remaining target production is set.
Page 516 HANDLE LOAD METER ATTACHMENTS AND OPTIONS When 15 seconds have passed after start of measure- ment, the indication of bucket load is cleared and dis- played as 0.0 t. The indication of remaining target load is displayed as 6.9 t. REMARK When you tilt back the bucket fully and raise the boom higher than that in the traveling posture, the measurement of the load starts.
Page 517 ATTACHMENTS AND OPTIONS HANDLE LOAD METER REMARK The indication of remaining target load may become -0.1 t due to the digit rounding error even if the previ- ous indication of remaining target load is displayed as 2.0 t and the current bucket load is displayed as 2.0 t as well.
Page 518 HANDLE LOAD METER ATTACHMENTS AND OPTIONS Dump 0.5 t of load onto a dump truck from 3.5 t of load that is currently in the bucket. After completing loading, lower the bucket to the travel posture. Then, raise the boom and measure the load re- maining in the bucket.
Page 519 ATTACHMENTS AND OPTIONS HANDLE LOAD METER CHECK PRODUCTIVITY Display of production Press the menu switch (1) on the standard screen. Press menu switch (1) and select “Load Meter” menu. Press UP switch (2) or DOWN switch (3) to select “Produc- tion Display or Reset”, and press ENTER switch (4).
Page 520 HANDLE LOAD METER ATTACHMENTS AND OPTIONS Clear of production On “Production Record” screen, press UP switch (2) or DOWN switch (3) to select the target material to be cleared, and press ENTER switch (4). When the confirmation screen for “Record Clear” is dis- played, press ENTER switch (4) to clear or press RETURN switch (5) to cancel clearing.
Page 521 ATTACHMENTS AND OPTIONS HANDLE LOAD METER Clear of total loading amount data On “Total Load Weight” screen, press UP switch (2) or DOWN switch (3) to select the target material to be cleared, and press ENTER switch (4). When the confirmation screen for “Total Load Weight Re- cord Clear”...
Page 522 HANDLE LOAD METER ATTACHMENTS AND OPTIONS Please set the bucket to carrying posture by full tilt accord- ing to the screen instructions. If the boom is lowered to the travel posture or below, the display on the screen changes. Raise the boom to the end according to the screen instructions.
Page 523 ATTACHMENTS AND OPTIONS HANDLE LOAD METER Press the menu switch (1) on the standard screen. Press menu switch (1) and select “Load Meter” menu. Press UP switch (2) or DOWN switch (3) to select “Calibra- tion”, and press ENTER switch (4). The screen changes to “Calibration”...
Page 524 HANDLE LOAD METER ATTACHMENTS AND OPTIONS If the boom is lowered to the travel posture or below, the display on the screen changes. Raise the boom to the end according to the screen instructions. At this time, raise the boom at the same speed as that of the actual operation.
Page 525 ATTACHMENTS AND OPTIONS HANDLE LOAD METER Press the menu switch (1) on the standard screen. Press menu switch (1) and select “Load Meter” menu. Press UP switch (2) or DOWN switch (3) to select “Calibra- tion”, and press ENTER switch (4). The screen changes to “Calibration”...
Page 526 HANDLE LOAD METER ATTACHMENTS AND OPTIONS If the boom is lowered to the travel posture or below, the display on the screen changes. Raise the boom to the end according to the screen instructions. At this time, raise the boom at the same speed as that of the actual operation.
Page 527 ATTACHMENTS AND OPTIONS HANDLE LOAD METER Press the menu switch (1) on the standard screen. Press menu switch (1) and select “Load Meter” menu. Press UP switch (2) or DOWN switch (3) to select “Calibra- tion”, and press ENTER switch (4). The screen changes to “Calibration”...
Page 528 HANDLE LOAD METER ATTACHMENTS AND OPTIONS Press the menu switch (1) on the standard screen. Press menu switch (1) and select “Load Meter” menu. Press UP switch (2) or DOWN switch (3) to select “Load Meter Display”, and press ENTER switch (4). On the confirmation screen for “Load Meter Display”, press UP switch (2) or DOWN switch (3) to select “OFF”, and press ENTER switch (4).
Page 529 ATTACHMENTS AND OPTIONS HANDLE LOAD METER Press the menu switch (1) on the standard screen. Press menu switch (1) and select “Load Meter” menu. Press UP switch (2) or DOWN switch (3) to select “Subto- tal SW Interlocking Horn Set”, and press ENTER switch (4).
Page 530: Handle External Power Supply Engine Preheater
HANDLE EXTERNAL POWER SUPPLY ENGINE PREHEATER ATTACHMENTS AND OPTIONS HANDLE EXTERNAL POWER SUPPLY ENGINE PREHEAT- The external power supply engine preheater is used to maintain the temperature of the coolant and lubricating oil after stopping the machine in cold areas, and make it easier to start the engine again. The external power supply engine preheater keeps the following coolant and lubricating oil warm.
Page 531: Fabricate External Power Supply Cable
ATTACHMENTS AND OPTIONS HANDLE EXTERNAL POWER SUPPLY ENGINE PREHEATER Always ground the ground cable In local areas, bury a ground rod in the ground • External power source input cable Use a 3-core cable Nominal cross-sectional area of one core should be 14mm² Use cabtire cable The length should be less than 30 m (Note 3) REMARK...
Page 532: Install External Power Supply System
HANDLE EXTERNAL POWER SUPPLY ENGINE PREHEATER ATTACHMENTS AND OPTIONS The machine input connector has 3 contacts. Each is provided with a code, so connect the cable core wires as shown in the chart of the figure. Terminology (Fig.3) Contact symbol Contact symbol Core wire to connect Core wire to connect...
Page 533: Check Operation After Completion Of Assembling
ATTACHMENTS AND OPTIONS HANDLE EXTERNAL POWER SUPPLY ENGINE PREHEATER The shape, size, and method of setting up the facility can be decided locally, but the specifications should be as follows. (1) Output electricity type Single phase AC (2) Output voltage 230 V (3) Power supply volume 6.3 kVA...
Page 535: Replacement Parts
REPLACEMENT PARTS...
Page 536: 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 537: 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 538 CONSUMABLE PARTS REPLACEMENT PARTS Item Part No. Part Name Q'ty Replacement interval Air cleaner 600-185-6100 Element assembly 426-70-13311 Tooth (02091-12050) (Bolt) (18) Integrated type bucket tooth (02290-12031) (Nut) (18) (178-70-14150) (Shim: 1.0 mm) (178-70-14160) (Shim: 0.5 mm) 426-70-13321 R.H. corner tooth 426-70-13331 L.H.
Page 539: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 540 RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS The symbols used in the lubrication chart are explained as follows.
Page 541: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
Check of fuel level Replace DEF tank breather element Replace DEF filter Drain METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Ambient Temperature, degrees Celsius Recommended Komatsu Reservoir Fluid Type Fluids Engine oil for EOS5W30-LA KDPF used in -25 °C...
Page 542 Note 3: Axle oil AXO80 is capable of preventing the brake and LSD (Limited Slip Differential) from creaking. When only AXO80 is recommended, use Komatsu genuine AXO80 or equivalent. Note 4: If the daily operation hours of the machine at ambient temperature above 45 °C exceed 12 hours, rec- ommend TO50 instead of AXO80.
Page 543: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
Note 8: The DEF freezes at -11 °C. If thawing is necessary, DEF system is automatically heated and thawed after the engine is started. RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
Page 545: Index
INDEX INDEX Symbols AJSS operation pilot lamp........3-35 Allowable water depth.........3-222 12-hour and 24-hour display mode....... 3-95 Alternate exit of cab........2-21,3-129 Alternate exit of cab - Check.......3-180 Alternate exit of cab - Lock......... 3-132 Alternate exit of cab - Open for emergency..3-130 Abnormal points detected up to previous day - Check.
Page 546 INDEX Brake disc - Check wear........4-72 Cold weather operation information....3-278 Brake dragging prevention guidance....3-43 Consumable parts...........7-3 Brake oil filter cartridge - Replace......4-61 Consumable parts list..........7-3 Brake oil pressure caution lamp......3-22 Contents of safety labels.........2-7 Brake oil temperature caution lamp...... 3-23 Control levers and pedals......
Page 547 INDEX Do not drop things inside machine......4-2 Engine overrun caution lamp........ 3-29 Do not get caught..........2-22 Engine related parts - Phenomena and actions..3-294 Do not go close to high-voltage cables....2-24 Engine shutdown secondary switch....3-122 Down switch............3-51 Engine side cover - Close securely......4-4 Dozing work............
Page 548 KMAX tooth - Replace.......... 4-33 Guide line display mode........3-85 Komatsu Closed Crankcase Ventilation (KCCV) 3-152 Guide to reduce vibration levels on machine..1-5 Komatsu Diesel Particulate Filter (KDPF) - Handle................3-143 Komatsu genuine lubricants........4-2 Komatsu genuine replacement parts...... 4-2 Handle electrical components.........4-9 KOMTRAX Plus..........
Page 549 INDEX Load meter - Use..........6-47 Machine monitor - Operate when starting switch is Load meter cancel switch........3-123 ON while operator ID input is set....3-14 Load meter sub total switch........ 3-123 Machine monitor - Operate when stopping engine in Load on dump truck..........
Page 550 Precautions for storing tires........2-46 Parking brake switch........... 3-112 Precautions for tire chain and adding ballast..3-257 Perform KOWA (Komatsu Oil Wear Analysis)..4-7 Precautions for towing and being towed....2-35 Periodic replacement of defined life parts.....2-45 Precautions for towing machine......3-283 Phenomena and actions for electrical system..
Page 551 INDEX Radiator fin and cooler fin - Clean......4-28 Seat belt anchor - Adjust........3-191 Radiator reservoir tank coolant filler cap - Open / Seat belt caution lamp.......... 3-24 Close............3-249 Seat cushion - Adjust in fore-after direction..3-183 Radiator reservoir tank coolant filler port cap - Lock..Seat heater - Use..........3-185 ..............3-249 Seat heater and ventilation - Use......3-186...
Page 552 INDEX Target object display - Select........ 6-47 Use proper tools............2-40 Temperature control switch......... 3-261 Use warning tags..........2-26 Tilt shock reduction level setting......3-69 User menu............3-52 Time - Set..............3-94 Tip type teeth - Replace........4-33 Tire - Handle..........2-45,3-255 V-shape loading..........
Page 554 WA600-8 WHEEL LOADER Form No. EENAM03470 ©2016 KOMATSU All Rights Reserved Printed in Belgium 03-2016...

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