Operation & Maintenance Manual: Wheel Loader

Operation & Maintenance SEAM042801 02
Manual
WA800-I
WHEEL LOADER
SERIAL NUMBERS wA80()-10()()1 and UP
FOREWORD
FOREWORD
This manual describes procedures for operation, handling, lubrication,
maintenance, checking, and adjustment. It will help the operator or anyone
realize peak performance through effective, economical and safe machine
operation and maintenance.
Please read this manual carefully BEFORE operating the machine.
Please continue studying this manual until proper operation is completely
reinforced into personal habit.
This manual describes the basic techniques. Skill is performed as the
operator or anyone get the correct knowledge and performance of the
machine.
Operation, inspection, and maintenance should be carefully carried out,
and the safety must be given the first priority. Safety precautions are in-
dicated with A marks and technical precautions with * marks in this
manual. The safety information contained in this manual is intended only
to supplement safety codes, insurance requirements, local laws, rules
and regulations.
Some photographs and illustration pictures are different from your ma-
chine as technical improvement is continuously reflected on it. Revision
to up-to-date manual’s content is performed in later editions.
This operation & maintenance manual may contain attachments and op-
tional equipment that are not available in your area. Please consult your
local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
ww -02595 -l-
BREAKING IN YOUR NEW MACHINE
BREAKING IN YOUR NEW MACHINE

Each machine is carefully adjusted and tested before shipment. However,
a new machine requires careful operation during the first 100 hours to
break in the various parts.
If a machine is subjected to unreasonably hard use at the initial operation
stage, the potential of performance will prematurely deteriorate and the ser-
vice life will be reduced. A new machine must be operated with care, partic-
ularly with regard to the following items.
After starting, let the engine idle l At the first 250 hours of * When replacing oil filter elements
for 5 minutes to allow proper operation, the machine should be (cartridges), check their interiors
engine warm-up prior to actual maintained in the following for dirt and dust. If heavily
operation. manner in addition to usual 250 collected, check for possible
Avoid operation with heavy loads hours service: cause before starting operation.
or at high speeds. I) Replacement of fuel filter car- * Hours of operation are indicated
Sudden starting or acceleration, tridge and transmission oil filter by the service meter.
unnecessarily abrupt braking and element
sharp turning should be avoided. 2) Checking and adjustment of
engine valve clearance
For replacement procedure and

details, see maintenance table in
the maintenance section.
-2- w-01239
CONTENTS
OPERATION MAINTENANCE
GENERAL LOCATIONS AND SPECIFICATIONS 4 PERIODIC MAINTENANCE .................... Bg
INSTRUMENTS AND CONTROLS .............. 5 BLEEDING AIR FROM CIRCUIT .............. 70
REMOVAL AND INSTALLATION OF BUCKET .... 34 PERIODICAL REPLACEMENT OF
USING ACCUMULATORS ..................... 38 SAFETY PARTS ......................... 73
CHECK BEFORE STARTING .................... 3g MAINTENANCE TABLE .................... 74
OPERATING YOUR MACHINE .................. 45 OIL FILLER AND LEVEL GAUGE POSITIONS . 78
ADJUSTMENT OF WORK EQUIPMENT ......... 54 EVERY 50 HOURS SERVICE ................ 7g
HANDLING THE TIRES ......................... 56 EVERY 100 HOURS SERVICE. .............. 80
TOWING.. ................................... 5g INITIAL 250 HOURS SERVICE .............. 83
TRANSPORTATION ........................... 61 EVERY 250 HOURS SERVICE ............... 83
COLD WEATHER OPERATION ................. 62 EVERY 500 HOURS SERVICE ............... 87
EVERY 1000 HOURS SERVICE ............. g0
EVERY 2000 HOURS SERVICE ............. 96
EVERY 4000 HOURS SERVICE ............. 104
WHEN REQUIRED ......................... 105
ADJUSTMENT .............................. 1 1B
TROUBLE SHOOTING GUIDE .................. 120
SERVICE METER ............................. 124
MACHtNE AND ENGINE SERIAL NUMBERS ..... 125
FUEL, COOLANT AND LUBRICANTS ........... 126
w-04273
-3-
GENERAL LOCATIONS AND SPECIFICATIONS
GENERAL LOCATIONS AND SPECIFICATIONS

PERFORMANCE
1. Bucket 6. Front wheel 1. Bucket capacity (Heaped) 10.5 m3
2. Lift arm 7. Lift cylinder 2. Travel speeds
3. Head lamp 8. Dump cylinder Forward Max. 28.0 km/h
4. Turn signal lamp 9. Tilt lever Reverse Max. 28.3 km/h
5. Rear wheel
OPERATING WEIGHT 86800 kg
ENGINE
1. Model Komatsu SA8V170-1 C diesel engine
l- 2. Flywheel horsepower (at 2000 rpm) 789 HP
NOTE:
Specifications are subject to change without notice
With cab and ROPS canopy
- W-02007
INSTRUMENTS AND CQNTROLS
INSTRUMENTS AND CONTROLS

MONITOR PANEL
This monitor system consists of monitor lamp groups @X$$@), meter group l To check the monitor system,
@I and warning lamp @J. turn the starting switch to ON
before starting the engine. Then
all the monitor lamps, the gauges
and the warning lamp light up for
about 3 seconds and the alarm
buzzer sounds for about 2
seconds. Three figures, 188, are
displayed on the speedometer
while the monitor system is
being checked. After -that all
lamps go off and the buzzer
stops. If any monitor lamp does
not light up, ask your Komatsu
distributor to inspect that monitor
lamp.
)r When the starting switch is
turned to ON, if the directional
lever is not at neutral, the warning
lamp will flash and the alarm
buzzer will continue to sound. If
this happens, return the lever to
neutral. The lamp will go out and
the buzzer will stop.
W-02008 -5-
Sr To check the monitor immediate- @CAUTION MONITOR @J METER GROUP

ly when the engine is stopped, GROUP This group consists of air pres-
wait for at least 30 seconds after (Emergency stop items) sure gauge, engine water tempera-
the engine is stopped. If any abnormality occurs while ture gauge, torque converter oil tem-
the engine is running, the appropri- perature gauge, fuel gauge,
@CHECK MONITOR ate monitor lamp will flash and the speedometer, service meter and
GROUP alarm buzzer will sound intermittent- pilot display.
(Check items before ly at the same time.
starting) * However, when the emergency @ WARNING LAMP
If there is any abnormality, the steering is being operated, only The warning lamp will flash
appropriate monitor lamp will flash. the monitor will flash. The alarm when there is an abnormality in any
* When the engine is started, these buzzer will not sound, and the @ group item.
monitor lamps will go off even if central warning lamp will not The warning lamp will flash and
there are abnormalities. light up. the alarm buzzer will sound when
* If any monitor lamp flashes, stop there is an abnormality in any @
@CAUTION MONITOR the engine or run it at a low idling group item or when the parking
GROUP speed, and repair it immediately. brake is applied, but the directional
(Caution items) lever is not at neutral.
If any abnormality occurs while
the engine is running, the appropri-
ate monitor lamp will flash to indi-
cate the abnormality.
* Even if any monitor lamp flashes,
the machine can operate, but it
should be repaired as soon as
possible.
-6- w-02009
A: CHECK MONITOR GROUP

(Check items before 1. BRAKE OIL LEVEL MONITOR 3. RADIATOR COOLANT LEVEL
starting) MONITOR
* Do not rely on the “CHECK MONI-
L?_J
TOR GROUP (Check before
starting)” only for the check
before starting. Always make the
check by referring to the section
on CHECK BEFORE STARTING. This monitor indicates a low
brake oil level. This monitor indicates a low
If the monitor lamp flashes, radiator coolant level.
check the oil level and add brake oil If the monitor lamp flashes,
as required. check the coolant level and add
water as required.
2. ENGINE OIL LEVEL MONITOR
* Park the machine on level ground
and check the monitor lamps.
0&A
* Confirm that these monitor
lamps light for about 3 seconds
after turning the starting switch
to ON. If any monitor lamp does
This monitor indicates a low oil not light, ask your Komatsu dis-
level in the engine oil pan. tributor to inspect that monitor
If the monitor lamp flashes, lamp.
check the oil level in the engine oil
pan and add oil as required.
W-01251 -7-
B: CAUTION MONITOR
GROUP 1. CHARGE MONITOR 2. FUEL LEVEL MONITOR
(Caution items)
ate monitor lamp and the warning
-
El + m
lamp will flash to indicate the abnor- I I I I
mality at the same time.

This monitor indicates an abnor- This monitor indicates there is
mality in the charging system while less than 155 liters of fuel in the
the engine is running. tank.
If the monitor lamp flashes, If the monitor lamp flashes, add
check the charging circuit. fuel.
* This monitor lamp flashes and
the alarm buzzer sounds, when
the starting switch is turned to
ON immediately after the engine
is started or immediately before
the engine is stopped. It does not
indicate an abnormality.
-8 - w-02010
c: CAUTION MONITOR
3. TRANSMISSION OIL FILTER GROUP 1. BRAKE LINE FAILURE
MONITOR (Emergency stop items) MONITOR
--
:
I I
( t.
1131 ate monitor lamp and the warning

lamp will flash and the alarm buzzer
will sound intermittently at the same
time.
/
This monitor indicates clogging This monitor indicates a drop in

of the transmission oil filter. the brake oil pressure when the
If the monitor lamp flashes, re- brakes are operated.
place the filter element. If the lamp flashes, stop the ma-
chine immediately and check the
* Park the machine on level ground brake system.
and check the monitor lamps.
* Confirm that these monitor * After checking and repair of
lamps light for about 3 seconds brake system, push in over-stroke
after turning the starting switch sensor rod. If this operation is not
to ON. If any monitor lamp does done, a buzzer and lamp will con-
not light, ask your Komatsu dis- tinue to warn of brake line
tributor to inspect that monitor trouble.
lamp.
w-01253
2. ENGINE OIL PRESSURE 3. COOLANT LEVEL MONITOR 4. AIR PRESSURE MONITOR

MONITOR
I
.. 1
49
‘.‘..
This monitor indicates a low This monitor indicates a low This monitor indicates a drop in
engine oil pressure. radiator coolant level. the air pressure in the air tank.
If the lamp flashes, the engine oil Check the coolant level when the If the lamp flashes, increase the
pressure is below the lower limit. Im- monitor lamp flashes, stop engine engine speed and wait until the
mediately stop the engine. and add water as required. lamp goes out.
This monitor lamp flashes and
the alarm buzzer sounds, when
the starting switch is turned to
ON immediately after the engine
is started or immediately before
the engine is stopped. It does not
indicate an abnormality.
Park the machine on level ground and check the monitor lamps.
Confirm that these monitor lamps light for about 3 seconds after turning
the starting switch to ON. If any monitor lamp does not light, ask your
Komatsu distributor to inspect that monitor lamp.
- IO- w-01254
5. COOLANT TEMPERATURE 6. TORQUE CONVERTER OIL 7. EMERGENCY STEERING

MONITOR TEMPERATURE MONITOR OPERATION MONITOR
This monitor indicates a rise in This monitor indicates a rise in If the engine stops while the ma-
the cooling water temperature. the torque converter oil temperature. chine is traveling or an abnormality
When the monitor lamp flashes, When the monitor lamp flashes, occurs in the pump circuit, the oper-
run the engine with no load at mi- stop the machine and run the ator will be warned that the
drange speed until the green range engine with no load at midrange emergency steering is in operation.
of the engine water temperature speed until the green range of the When flashing begins, stop the ma-
gauge lights. temperature gauge lights. chine immediately.
Sr Park the machine on level ground and check the monitor lamps.
* Confirm that these monitor lamps light for about 3 seconds after turning
the starting switch to ON. If any monitor lamp does not light, ask your
Komatsu distributor to inspect that monitor lamp.
w-02011 - 11 -
D: METER GROUP
PILOT DISPLAY 1. PARKING BRAKE PILOT LAMP 2. PILOT LAMP FOR WORKING
When the starting switch is LAMP
turned to ON, this lights up to indi-
cate that the display items are
working.
I J
rl 0
hll
This lamp lights up when the This lamp lights up when the
parking brake is applied. working lamps are switched on.
3. ENGINE PRE-HEATING
MONITOR
When using APS (automatic

priming system) and when starting,
switch on lamp and you will be in-
formed that pre-heating has started.
W-01256
4. AFTERHEATING MONITOR 5. TRANSMISSION CUT-OFF 6. AIR PRESSURE GAUGE

SELECTOR PILOT LAMP
I 1
Redw
Green
Red
When using APS (automatic This lamp lights up when the This gauge indicates the air pres-
priming system) in cold weather, transmission cut-off selector switch sure in the air tank. The green range
and when starting, after the engine is turned to ON. should be lighted during normal
starts, the lamp will flash until the * If the monitor lamp is ON and the operation.
water temperature reaches 2O”C, left brake pedal is depressed, the If the red range lights up during
informing you that afterheating has transmission will be returned to operations, the alarm buzzer will
started. neutral. sound, the warning lamp will flash,
and the air pressure monitor lamp
will flash.
If this happens, stop the
machine, increase the engine speed
and wait until the green range lights
up.
Sr If the air pressure drops even
low,er, the parking brake will be
automatically applied.
W-02012 - 13-
7. ENGINE COOLING WATER 8. TORQUE CONVERTER OIL 9. FUEL GAUGE

TEMPERATURE GAUGE TEMPERATURE GAUGE
Red Red
Green
Green
Red
White
/
Green
This gauge indicates the tem- This gauge indicates the tem- This gauge indicates the amount
perature of the cooling water. If the perature of the torque converter oil. of fuel in the fuel tank. If there is
temperature is normal during If the temperature is normal during enough fuel in the tank while the
operation, the green range will light. operation, the green range will light. engine is running, the green range
If the red range lights during If the red range lights during lights. If the red range lights, there is
operation, the alarm buzzer will operation, the alarm buzzer will less than 155 liters of fuel in the
sound, the warning lamp will flash sound, the warning lamp will flash tank.
and the coolant temperature moni- and the torque converter oil tem- When the red range lights, add
tor lamp will flash at the same time. perature monitor lamp will flash at fuel.
If this occurs, stop the machine and the same time. If this occurs, stop
run the engine with no load at mi- the machine and run the engine
drange speed until the green range with no load at midrange speed until
lights. the green range lights.
- 14- w-02013
10. TURN SIGNAL PILOT LAMP 12. SPEEDOMETER 13. SERVICE METER
When the turn signal lamp This meter indicates the running This meter shows the total
flashes, the pilot lamp also flashes. speed of the machine. operation hours of the machine.
+ If the wiring of the turn signal * A speedometer for MPH is also The service meter advances while
lamp is disconnected, the pilot available. the engine is running - even if the
lamp will flash faster. machine is not traveling.
Refer to the section “SERVICE
11. HIGH BEAM PILOT LAMP METER”.
* While engine is running, green
pilot lamp on the service meter
flashes to show the service
meter advances.
This lamp lights up when the

head lamp is at high beam.
w-01259
- 15-
SWITCHES
1. TRANSMISSION CUT-OFF This switch selects the operation
SELECTOR SWITCH of the left brake pedal. Normally, A If the machine has to be
put this switch in ON position. started on a slope, always turn
@ OFF: the transmission cut-off selec-
Acts as normal brake (like right tor switch to OFF and depress
brake pedal). the left brake pedal. Then dep-
@ ON: ress the accelerator pedal
Acts as normal brake, but also while releasing the left brake
switches transmission to NEUTRAL. pedal to start the machine off
* If the switch is at ON, the trans- slowly.
mission cut-off selector pilot
lamp will light up. Put the switch to the desired po-
sition according to working con-
dition to make operation easy.
- 16- ww -02014
2. FUEL CUT-OFF SWITCH 3. ENGINE LOW IDLING 4. HAZARD LAMP SWITCH

SELECTOR SWITCH
Engine fuel consumption will be The engine low idling speed can This switch is used in
cut. be switched between two levels. emergencies, such as when the ma-
When using APS (automatic 0 ON: chine breaks down.
priming system) in cold weather, The engine low idling speed is set ON: All turn signal lamps flash.
use when starting. to approx. 850 rpm. This is used
OFF: on busy jobsites where it is * All turn signal lamps and pilot
Fuel is not supplied to the engine. necessary to reduce the cycle lamp on the steering column
ON: time. flash.
Fuel is supplied to the engine. @ OFF:
When hand is removed from OFF This sets the engine low idling A Do not use this switch unless
position, switch returns to ON speed to approx. 650 rpm. This abnormality is occured.
position. is used for normal operations at
For detailed method of usage, low idling, such as when waiting
refer to “starting in cold for dump trucks.
weather”.
ww -02015
- 17-
5. PARKING BRAKE SWITCH

This switch operates the parking
brake.
A Always apply the
brake when leaving
parking
the ma-
@I ON position: chine or parking it.
The parking brake is applied, and
the parking brake pilot lamp lights If the directional lever is placed in
F (FORWARD) or R (~~EVERSE)
$OFF position: with the parking brake applied,
The parking brake is released. the warning lamp will flash and
the alarm buzzer will sound.
When the starting switch is
turned to OFF, the parking brake
is automatically applied.
Before starting the engine, turn
the parking brake switch to ON,
then turn it to OFF.
The machine does not start
when the directional lever is
operated with parking brake
applied.
- 18 - ww -02016
6. WORKING LAMP SWITCH 7. PREHEATER SWITCH

(APS (automatic priming
/ system) switch)
/- OFF
ON
/
When the front and rear working

lamps are turned ON, the pilot lamp
and illumination lamp for monitor When using APS, engine intake
panel will also light up. air is heated. Usually, the switch is
ON: Working lamps are ON. in the OFF position.
@ OFF position: @ ON oosition:
A When travelling on public The pre-heat
working.
function is not If the switch is moved again from
AUTO position and upward to
roads, turn the working lamps
OFF. @ AUTO position: ON, APS operation will begin.
When engine water temperature If the switch is released when at
is below 13”C, APS starts. the ON position, it will automati-
After starting, maintain this posi- cally return to AUTO.
tion until the lamp of the after- Method of using preheater
heating monitor goes out. switch, refer to the section
* Before starting APS, put the “starting in cold weather”.
switch to ON and then put it to When the engine settle down
this position. after starting, put the preheater
switch in OFF position.
WW -02017 - 19-
8. STARTING SWITCH 9. HORN BUTTON
...“‘.. ‘_
OFF ,:.,
:
,‘:: . . .._ :,
jj
,: :
;’ :
,. :
I :
: : 9 “.i : :
ii _,I. .>, : :
+
),.‘. F’,.’ ‘.::.‘,.
;’
‘., :
,._ .:.. -- .”
When the button in the center of

This switch is used to start or the steering wheel is pressed, the
stop the engine. horn will sound.
OFF START
Key insertion-withdrawal posi- At this key position, the starting
tion. None of electrical circuits motor will crank the engine. Release
activate. the key immediately after starting,
The hazard lamp, parking lamp and the key will return automatically
and the room lamp will remain on, to ON.
however, when the switch is turned
OFF.
To stop the engine, turn the
switch to OFF.
ON
Charging, lamp and accessary cir-
cuits activate. Keep key at ON after
starting.
- 20 - W-02018
10. LAMP SWITCHES

(for lamps, turn signal lamps,
dimmer switch)
Lamp switch Turn signal lever + When the steering wheel is

Position 0 - PZ : This lever operates the turn turned to the neutral position, the
Parking lamp lights up. signal lamps. turn signal lever will return auto-
Position OFF @ -. . : @LEFT TURN: matically to OFF. If not, return the
Lamps go off. Push lever FORWARD. lever to OFF manually.
Position @ :D~OS : @RIGHT TURN:
Clearance lamps, tail lamps and Pull lever BACK. Dimmer switch
machine monitor lighting light up. This switches the head lamp be-
Position @ 3D. : * When the lever is operated, the tween high beam and low beam.
Head lamps light up in addition to turn signal pilot lamp will also @ Low beam
the lamps in position @ -DUO light up. @ High beam
* The lamp switch can be operated
regardless of the position of the
lever.
w-02019 -21 -
11. FRONT WIPER SWITCH 12. REAR WIPER SWITCH
I’ +_- Q .-
1 t- ‘- ON
I’ .\ f3
t-
- OFF - OFF
CT
8
@ The wiper is actuated at low When this switch is pulled to ON

speed. position, wiper operates on rear
@ The wiper works at high speed. glass.
When this switch is turned When this switch is turned
clockwise, solvent will be sprayed clockwise, solvent will be sprayed
on glass. on glass.
- 22 - w-03020
13. CIGARETTE LIGHTER 14. ROOM LAMP SWITCH
OFF a ON
This is used to light cigarettes. When this switch is moved to ON

To use, push the lighter in. After the position, room lamp will light.
few seconds it will spring back. At
that time, remove the lighter and
light your cigarette.
w-02021 - 23 -
PEDALS AND LEVERS
1. ACCELERATOR PEDAL 2. BRAKE PEDALS

This pedal controls the engine Right brake pedal Left brake pedal
speed and output. The engine speed The right brake pedal operates The left brake pedal operates the
can be freely controlled between the wheel brakes, and is used for wheel brakes, and if the transmis-
low idling and full speed. normal braking. sion cut-off selector switch is at
ON, it also returns the transmission
A On hills, use the right brake to neutral.
pedal or use the left pedal with If the transmission cut-off selec-
the transmission cut-off selector switch is at OFF, the left brake
tor switch put in OFF. pedal acts in the same way as the
right brake pedal.
A repeatedly
Do not use the
unless
brake pedals
necessary.
A Do not use the brake pedals as

footrests. Use them only when
applying the brakes.
* When the accelerator is being

used for operating the work
equipment, always use the left
brake pedal to slow or stop the
machine after putting the trans-
mission cut-off selector switch in
ON.
- 24 - ww-02022
3. DIRECTIONAL LEVER 4. SPEED CONTROL LEVER

@Forward
\\ A @Reverse
@ Neutral
+ The engine cannot be started if

the directional lever is not at N 1 St
(neutral). 2nd
* When operating the directional 3rd
lever, place your hand on a steer-
This lever is used to change the ing wheel and operate it by your
direction of travel of the machine. fingers.
This lever controls the travel
speed of machine.
This machine has a 3-
FORWARD, 3-REVERSE speed
transmission. Place the speed con-
trol lever in a suitable position to
obtain the desired speed range.
1 st and 2nd speeds are used for
working.
3rd speed are used for traveling.
w-02023 - 25 -
5. SPEED CONTROL LEVER 6. STEERING COLUMN TILT

STOPPER
This stopper prevents the speed This lever allows the steering * Range of adjustment:
control lever from entering the 3rd column to be tilted forward or 100 mm (stepless)
position, when working. backward.
Position @ Pull the lever up and move the A Stop the machine before ad-
Stopper actuated. steering wheel to the desired justing the angle of the steering
Position @ position. Then push the lever down wheel.
Stopper released. to lock the steering wheel in
position.
- 26 - WW-02024
7. LIFT ARM CONTROL LEVER

This lever is used to operate the
lift arm.
0 Raise ( at )
@ Hold ( % 1:
The lift arm is kept in the same
position.
@ Lower ( d 1
@I Float ( & ):
The lift arm moves freely under
external force.
+ When the lift arm control lever is
pulled further from 0 position,
the lever is stopped in this posi-
tion until lift arm reaches the
preset position of kick-out, and
the lever is backed to hold
position.
w-02025 - 27 -
8. BUCKET CONTROL LEVER 9. SAFETY LOCK
Tilt
This lever operates the bucket. * When the bucket control lever is This is used to lock the lift arm
pulled further from @ position, and bucket control levers.
@ Tilt ( % 1 the lever is stopped in this posi-
@Hold ( s ):
The bucket is kept in the same
tion until bucket reaches the
preset position of bucket
A When parking or leaving the
machine, or when the perform-
position. positioner, and the lever is ing maintenance, always lower
@ Dump ( k’ 1 backed to hold position. the bucket to the ground, put
the work equipment levers in
hold position and check that
safety lock lever is locked.
- 28 -
W-04274
DUST INDICATOR CIRCUIT BREAKER (MAIN) SAFETY BAR
This device indicates clogging of This prevents damage to the The safety bar is used during
the air cleaner element. When red electrical components and electric maintenance or when transporting
piston (I ) appears in the transparent wiring. the machine. It locks the front frame
part of this indicator, the element is When the breaker has been and rear frame, and prevents the
clogged. immediately clean element. actuated, press the reset button to front and rear frames from bending.
After cleaning, push indicator reset the system. However, if the cir-
button (2) to return red piston to cuit breaker is actuated again after A Always use the safety bar for
original position. the button is pressed, or the circuit maintenance or when trans-
There are two dust indicators on breaker is frequently actuated, there porting the machine.
the front of the engine hood behind may be a short circuit in the electri-
the cab. cal system. In such cases, contact A Always remove the safety bar
your Komatsu distributor for repairs. during normal travel
* The main breaker is not reset for operations.
45 seconds after the breaker is
actuated.
ww -02026 - 29 -
CIRCUIT BREAKER
Breaker arrangement and circuit
Circuit breaker is in cover behind

the operator’s seat. Circuit breaker I
When breaker has been
Breaker
actuated, press the reset button to No. Circuit
capacity
reset the system.
Pressing the reset button wilt 0 20A Starting switch
reset all six breakers in the breaker 10A Hazard lamp

0
box at the same time.
1OA Left head lamp
a
0
When resetting the breaker,
0 10A Right head lamp
always turn off the electrical
current before starting (turn 20A Left side clearance lamp
0
starting switch OFF).
8 10A Right side clearance lamp
- 30 - WW -02027
Circuit breaker II Circuit breaker IV
Breaker Breaker
No. Circuit No. Circuit
capacity capacity
Head lamp, parking lamp
0 20A
Clearance lamp, Tail lamp
0 20A Air conditioner (Fan outside room)
0 10A Turn signal lamp 0

I
10A
I
Air conditioner (Fan inside room)
0 10A Brake lamp, Back up lamp 0 I 10A Radio, Room lamp
0 IOA Transmission control valve 10A Cigarette lighter
Rear wiper
0 10A Horn, Parking brake 0 10A
Rear washer
@I I
10A (
I
8 10A
Front wiper
Front washer
Circuit breaker III Circuit breaker V
Breaker
No. Circuit
capacity
I
0 20A APS (automatic priming system)
0 IOA APS (automatic priming system)
0 IOA Monitor panel @ ) tOA ( Rear working lamp
0 10A
Bucket positioner
Boom kick-out @ I 1 OA ( Side working lamp
0 10A Rear working lamp 0 I IOA -
8 10A Front working lamp @ I IOA
w-04275 -31 -
OPERATOR’S SEAT RIGHT SIDE ARMREST

The seat adjustment should be 8: Seat angle adjustment
checked at the beginning of each Move lever (2) up, set the seat to
shift and when operators change. the desired angle, and release the
lever.
The seat can be tilted up or down
about 3”.
C: Seat cushion adjustment

Rotate grip (3) under the seat to
adjust scale (4) on the cushion ad-
justment to your own weight. (50 to
120 kg)
Height adjustment
D: Backrest adjustment Loosen bolts (I) to move the arm
Pull lever (51, move the backrest rest to the desired position, and
to the best position and release the tighten the bolts.
lever. The backrest can be set to 1 1 Angie adjustment
steps. Loosen bolts (2) to move the
armrest to the desired angle and
E: Seat height adjustment tighten the bolts.
A: Forward-backward adjustment Move lever (6) upward, set the
Move lever (1) to the right, move seat to the desired height and
the seat to the best position and release the lever.
release the lever. The seat can be The seat can be set within
moved forward or backward within 50 mm.
a range of 140 mm in 7 stages.
- 32 - w-01275
SEAT BELT
3. Sit in the seat. Hold buckle (2)

and insert (3) into the buckle (2).
Check that the belt has locked by
pulling it.
4. When removing the belt, raise
the tip of the buckle lever to
release it. ii) To lengthen, pull the belt while
* When leaving the operator’s holding it at a right angle to
seat, release the seat belt and buckle or insert.
A Before fastening the seat belt, hang it over the arm rest.
* Fasten belt along your body with-
inspect the securing brackets
and belt for abnormal out kinking it. Adjust the lengths
conditions. of the belt on both the buckle
Fasten the belt and remove it in and the insert sides so that the
the following manner. buckle is located at the mid-point 5. When operating a machine
1. Adjust the seat so that the brake of your body front. equipped with ROPS, be sure to
pedal can be depressed all the Adjust the belt length in the fol- use the seat belt.
way with the operator’s back lowing manner. sr Inspect bolts and fittings on the
against the backrest. i) To shorten the belt, pull the chassis for tightness. Retighten
2. After positioning the seat, install free end of the belt on either any loose bolts to 2 to 3 kgm
the tether belt (I 1. With the seat thebuckle body or insert side. torque.
* If the seat is scratched or frayed
ly
unoccupied, tense the belt slight-
across the seat and install. or if any of the fittings are broken
A Check that there are no kinks or deformed from long service,
in the belt. replace the seat belt immediately.
W-03572 - 33 -
REMOVAL AND INSTALLATION OF BUCKET

When removing or installing Removing the bucket
bucket for transporting, use the fol- I. Loosen retainer mounting bolts 2. Loosen lock bolt (3) and remove
lowing steps: on the bucket link pin part and cam (4).
the bucket pin part, then remove
A ground,
Park the machine on level
set the safety bar on
retainer (1) and shim (2).
the frame, ground the bucket,

shut down the engine, apply
the parking brake and place
blocks under the tires.
- 34 - w-03777
3. Remove mounting bolt (5) of 4. Sling the bucket link, then pull Installing the bucket
flange. out the bucket link pin. 1. Assemble O-ring (2) on flange
* Before pulling pin, be sure to or Secure the bucket link to the tilt (1) of bucket pin.
remove mounting bolt of flange. lever with wire. * Assemble O-ring after coating
Otherwise the seal will be with grease.
damaged.
2. Check that there is nothing

5. Pull out and remove pin (6) on wrong with the oil seal (2) and
both sides of bucket. dust seal (3) that are assembled
6. Disconnect lift arm and bucket, on flange (I), and that dust seal
is assembled 0 to 0.5 mm from
edge of flange (I), or that there is
no clearance between dust seal
(3) and oil seal (2).
W-03778 - 35 -
* After inserting, rotate flange 1 to * When inserting pin, do not

2 times with the hand until the damage O-ring, and coat with
flange settles in with the seal. engine oil or grease.
a Insert the flange until there is no 8. Adjust number of shims so there
clearance between the inner face is less than 0.2 mm clearance
of the flange and the edge face between flange (I) and bucket
a-0 of the bushing. hinge plate, then install the
mounting bolts of flange.
3. Fill the space between oil seal (2)

Bucket
and dust seal (3) with grease. G/
Shim
/
Bushing
Grease 6 Assemble mounting side of the

4. Coat the tip of the outer circum- flange the same way. * When selecting the shim, mea-
ference of the lift arm bushing 7. Assemble lift arm to bucket and sure the clearance for each
with grease. insert hinge pin. separable shim mount at the top
5. Insert flange (1) in lift arm. Do not * When attaching bucket to lift and bottom, and assemble the
tap with a hammer. arm, do not hit flange (I) with optimum shim at each location.
Be sure to insert by hand. the bucket. If the bucket hits the Be careful that the flange is not
flange, the oil seal (2) and dust at an angle.
seal (3) will be damaged.
- 36 - w-03779
9. Attach the lock plate for bucket 10. Install retainer (I) and shim (2)
pin (5) to the block on the hinge (Standard thickness: 2.5 mm)
plate and then secure the lock to bucket pin (5).
plate with cam (4).
Sr Adjust the thickness of the

shim so that the clearance be-
tween the end surface of the re-
tainer and the hinge plate is re-
duced to less than 0.2 mm.
1 1. install bucket link pin according
to the procedure 1 to 10.
12. Lubricate the bucket pin and
bucket link pin by referring to
the section EVERY 2000
HOURS SERVICE.
W-03780 - 37 -
USING ACCUMULATORS
USING ACCUMULATORS
PRECAUTIONS FOR
MAINTENANCE
The accumulators are on the Never strike a charged accumula-
right inside of the rear frame under tor or expose it to flames.
the center platform. Never weld piping to or cut open-
ing in an accumulator.
A The accumulators are filled Never overhaul or dispose of an
accumulator without first bleed-
with highly pressurized
nitrogen. To avoid explosions, ing out all the nitrogen through
observe the following the air bleeder valve.
precautions.
* Always handle an accumulator
If accumulators breakdown or with the utmost care!
have trouble, immediately ask * Have your Komatsu distributor
your Komatsu distributor to check the gas pressure once a
make the repairs. year!
Only Komatsu personnel and
those licensed to service high
pressure equipment may re-
charge an accumulator with
nitrogen.
- 38 -
ww -02031
CHECK BEFORE STARTING

Pre-operation checks forestall machine trouble. Never neglect them.
a. WALK-AROUND CHECK b. CHECK MONITOR PANEL c. CHECK AND REFILL COOLANT

1. Check bucket for wear.
2. Check transmission case joints
for oil leak.
3. Check brake system for air leak
and oil leak.
4. Check tightness of air cleaner
mounting bolt.
5. Check tightness of battery
terminal.
6. Check radiator for water leak.
7. Check around the engine for Turn the starting switch to ON. Remove radiator cap (1) on rear
water and oil leaks. Check that all the monitor lamps, machine body, and check that cool-
8. Check axle for oil leak. the gauges and the warning lamp ing water is filled up to depth in-
9. Check hydraulic tank joint for light up for about 3 seconds and dicated by shadowed portion. If not,
oil leak. the alarm buzzer sounds for add water.
10. Check for oil leak at high pres- about 2 seconds. + If the volume of coolant added is
sure hose and high pressure If any monitor lamp does not more than usual, check for possi-
hose joints. light up, ask your Komatsu dis- ble water leakage.
tributor to inspect that monitor * Confirm that any oil is not in
lamp. coolant.
Always make the check by refer-
ring to this section on CHECK
BEFORE STARTING.
W-04276 - 39 -
d. CHECK OIL LEVEL AND REFILL

IN ENGINE OIL PAN
A Do not remove the cap while 1. Open the inspection ‘window at

the rear left side of the machine.
t When checking the oil level, park
the machine on a level surface,
cooling water is hot. Hot water
may spout out. 2. Use dipstick (G) to check the oil stop the engine and wait for 15
Before removing radiator cap, level. minutes before checking.
turn cap slowly to relieve inner 3. The oil level should be between
pressure. mark L and H, if necessary, add
oil at oil filler (F).
f The type of lubricant used
depends on the ambient tempera-
ture. Select according to the
table “FUEL, COOLANT AND
LUBRICANTS”.
+ After checking, be sure to tighten
the handle of (G) and (F).
- 40 - W-04277
e. CHECK FUEL LEVEL AND f. CHECK ELECTROLYTE LEVEL

REFILL FUEL IN BATTERY
1. Check the fuel level using fuel * Fuel capacity: 1200 II Open the battery box covers.
gauge (G) on the monitor panel. * When adding fuel, never let the If the electrolyte level is lower
2. Upon completion of work, pour fuel overflow. This may cause a than the prescribed level (IO to
in addition fuel from filler (F) until fire. 12 mm above the plate), supply
the fuel tank is full. distilled water.
Should any of the acid be spilt,
have it replenished by the nearest
battery shop with acid of the cor-
rect specific gravity.
When inspecting electrolyte
level, clean the air hole of the bat-
tery cap.
W-04278 -41 -
g. CHECK DUST INDICATOR h. DRAIN WATER FROM AIR

TANK
Alf the electrolyte gets on your When air cleaner element is Upon completion of work, open
skin or clothes, immediately clogged, the red piston of dust in- drain valves (11, (2), (3) and drain
wash with plenty of clean dicator (I ) (2 points) reaches service water out of the tank.
water. level and g&s locked.
In that case, clean element refer-
A To avoid gas explosions, do not ring to the section “WHEN
bring fire or sparks near the REQUIRED”.
battery. After cleaning element, push
button to return red piston.
- 42 - w-04279
i. CHECK AND REFILL OF OIL IN i. CHECK FOR SEDIMENT AND

BRAKE OIL TANK WATER IN THE WATER
SEPARATOR
Check using sight gauge (I) of * The type of lubricant used de-
the brake oil tank on the left side pends on the ambient tempera-
of the machine to check that the ture. Select according to the The water separator separates
oil level is between the MAX and table “FUEL, COOLANT AND water mixed in the fuel. If float (2) is
MIN marks. LUBRICANTS”. at or above red line (I), drain the
If the oil level is low, open the water. For the draining procedure,
cover at the top of the platform, A Never use the vegetable oil. see section “WHEN REQUIRED”.
then open cap (2) and add engine * Even if a water separator is
oil. installed, be sure to check the
fuel tank to remove water and
sediment in the fuel.
WW-02036 - 43 -
k. CHECK THAT PARKING r. CHECK STEERING PLAY; t. CHECK ELECTRICAL WIRING

BRAKE WORKS PROPERLY. CHECK THAT STEERING Check for any sign of
WORKS PROPERLY. disconnection or short circuit in the
I. CHECK THAT BRAKES WORK electric wiring. Check also for loose
PROPERLY. s. CHECK THAT BACK-UP terminals and tighten any loose
BUZZER SOUNDS PROPERLY. parts.
m.CHECK THAT HORN SOUNDS Check the following points carefully.
PROPERLY. l Battery
0 Starting motor
n. CHECK THAT LAMPS FLASH l Alternator
PROPERLY; CHECK FOR DIRT

OR DAMAGE.
o. CHECK DIRECTION OF REAR

VIEW MIRROR; CHECK FOR
DIRT OR DAMAGE.
p. CHECK THAT ENGINE

EXHAUST GAS COLOR AND
SOUND ARE NORMAL.
q. CHECK THAT GAUGES AND

INSTRUMENTS WORK
PROPERLY.
- 44 - W-04280
OPERATING YOUR MACHINE

BEFORE STARTING THE
ENGINE
1 Carry out an initial inspection. 4. Is the directional lever (2) in N
(For details of the inspection, see (neutral) position?
CHECK BEFORE STARTING.)
2. With your back against the back

rest of the operator’s seat, adjust
the seat position so that the
brake pedals can be easily
depressed. * The engine will not start while
the directional lever (2) is in any
? Is the parking
w. brake switch (I) in position other than N (neutral).
ON position?
5. Are work equipment control
levers (3) locked by safety lock
(4) ?
W-02033 - 45 -
TO START THE ENGINE

6. Turn the key of starting switch 3. When engine is started, release
(5) to the ON position. the key of starting switch (2) and
the key will return automatically
OFF
to ON.
OFF
7. In (6) of machine monitor,

confirm that there is no warning * If engine will not start, repeat the
indication of following: 1. Depress accelerator pedal (1) starting procedure after about 2
l brake oil amount lightly. minutes.
0 engine oil amount 2. Turn the key of starting switch
l radiator water level. (2) to the START position to
When there is a warning start engine.
indicator in the monitor, refer to
item, “A check group” OFF
explanation of each device.
- 46 - w-02039
CHECKS AFTER STARTING

Do not leave the key in START After starting make the following 3. Check if the exhaust color is
for more than 20 seconds. checks. normal or whether there is any
To start engine in cold weather, abnormal noise or vibration.
refer to COLD WEATHER * Avoid abruptly accelerating the
OPERATION. engine until the completion of
When using fuel with a low warm-up.
cetane value, starting the engine * Do not run the engine for more
is usually difficult in normal tem- than 20 minutes at low idling or
peratures. In such cases, use the at high idling.
procedure for starting in cold * When warming up the engine for
weather to make it easier to start at least 20 minutes, load it from
the engine. time to time, or if this is not possi-
Depress accelerator pedal (1) ble run the engine at medium
Special starting lightly and run the engine with no speed.
When starting after running out load at midrange speed for about * For machines where the air dryer
of fuel, fill with fuel, then fill the fuel 5 minutes. is installed as an option, in cold
filter cartridge with fuel and bleed After warm-up run is completed, temperatures below - 1 OX,
the air from the fuel system before check monitor lamps for proper when operating the machine
starting. operation. after it has been stopped for
Refer to FUEL FILTER in every Continue to run the engine at several hours, run the engine for
500 hours services. light load until the green ranges at least 10 minutes after starting
of the engine water temperature before moving the machine.
gauge and torque converter oil
gauge light.
W-04281 - 47 -
TO MOVE THE MACHINE OFF

3. Depress right brake pedal (I), 5. Release right brake pedal (11,
and turn parking brake switch (2) then depress accelerator pedal
to OFF (release) to release the (5) to move the machine off.
parking brake.
A If the machine has to be started
on a slope, always turn the
transmission cut-off selector
switch to OFF and depress the
left brake pedal. Then depress
the accelerator pedal while
releasing the left brake pedal
1. Check that the warning item is + When the parking brake is applied to start the machine off slowly.
not displayed on the monitor with parking brake switch (2) put
panel. in OFF, put switch (2) to ON and
2. Free the safety lock for work return it to OFF again.
equipment control lever. Bring
the work equipment in the travel- 4. Set speed control lever (3) and
ing posture. directional lever (4) to the desired
position.
60 - 70cm
- 48 - ww -02041
CHANGING GEAR SPEED CHANGING DIRECTION

There is no need to stop the ma- Place directional lever (1) in the
chine even when switching between desired position.
FORWARD and REVERSE.
A Before changing direction,

check that it is safe.
A WARD
Move speed control lever (1) to
the desired position. Never change between FOR-
and REVERSE at high
speed.
Sr To use 1 st or 2nd speeds for dig-

ging and loading operations,
actuate speed control lever
W-04282 - 49 -
TURNING TO STOP THE MACHINE

+ Turn the steering wheel lightly to
follow the machine as it turns.
When turning the steering wheel
fully, do not turn it beyond the
end of the stroke.
Itis dangerous
A chine to turn the ma-
suddenly at high speed,
or to turn on steep hills.
A When the engine stops while

When traveling, use steering the machine is traveling, the 1. Release accelerator pedal (I 1,
wheel (II to turn the machine. emergency steering will and depress brake pedal (2) to
+ With this machine, the front operate. But, since this device stop the machine.
frame is joined to the rear frame is an emergency steering
at the center of the machine by device, never stop the engine 2. Place directional lever (3) in N
the center pin. The front and rear while the machine is traveling. (neutral).
frames bend at this point, and It is especially dangerous on a
the rear wheels follow in the hill (For machines equipped
same track as the front wheels with emergency steering).
when turning.
- 50 - ww -02043
TO STOP THE ENGINE

3. Turn parking brake switch (4) to 4. Operate the work equipment
ON to apply the parking brake. lever and lower the bucket to the
ground, then lock the safety lock
lever for work equipment lever.
ON
Run the engine at low idling

* When the parking brake is speed for about 5 minutes to
applied, the transmission is auto- allow it to gradually cool down.
matically returned to neutral. A Stop the machine in a safe
Return starting switch (I) to the
place on firm level ground. If
the machine has to be stopped OFF position and remove the key.
on a slope, put blocks under
the wheels. In addition, dig the OFF
bucket into the ground to in-

crease safety.
W-04283 -51 -
MAXIMUM DEPTH OF WATER PRECAUTIONS WHEN DRIVING

If the engine is abruptly stopped When working in water or on UP OR DOWN SLOPES
before it has cooled down, swampy ground, do not let the
engine life may be greatly water come above the bottom of Lower the center of gravity when
shortened. Consequently, do not the axle housing. turning.
abruptly stop the engine apart * After finishing the operation, When turning on slopes, lower
from an emergency. wash and check the lubricating the work equipment to lower the
In particular, if the engine has points. center of gravity before turning. It is
overheated, do not abruptly stop dangerous to turn the machine with
Axle housinq
it but run it at medium speed to the work equipment raised.
allow it to cool gradually, then
stop it.
IF WHEEL BRAKE DOES NOT

WORK
If the machine is not stopped by
depressing brake pedal, use the
parking brake to stop the machine.
- 52 - w-01297
Braking on downhill slopes If engine stops

When driving down a slope, put If the engine stops on a slope,
the speed control lever in a low depress the right brake pedal fully.
speed position and fully apply the Next, lower the work equipment to
engine brake. Run the engine at the ground and apply the parking
medium speed, and to apply the ser- brake. Then put the directional and
vice brake, depress the right brake speed control levers in neutral, and
pedal. start the engine again. (If the direc-
If the speed control lever is not tional lever is not in neutral, the
placed in a proper speed position, engine will not start.)
the torque converter oil may
overheat. If it overheats, place the
speed control lever in the next lower
gear speed to lower the oil
temperature.
If the temperature gauge does
not indicate the green range of the
scale even with the lever in the 1 st
speed position, stop the machine,
place the lever in neutral, and run
the engine at medium speed until
the gauge indicates the green range.
W-01298 - 53 -
ADJUSTMENT OF WORK EQUIPMENT

ADJUSTING BOOM KICKOUT
The boom kickout makes it possi- 1. Raise the bucket to the desired 3. Loosen two nuts (4) to make a
ble to set the bucket so that it auto- height, set the lift arm control clearance of 3 to 5 mm between
matically stops at the desired lifting lever at HOLD and lock the lever plate (2) and the sensing surface
height (lift arm higher than horizon- in position. Then stop the engine of proximity switch (3). Then
tal) and the bucket positioner makes and adjust as follows. tighten the nuts to hold in
it possible to set the bucket so that 2. Loosen two bolts (I), and adjust position.
it automatically stops at the desired plate (2) so that the bottom edge Sr Tightening torque:
digging angle. The setting can be ad- is in line with the center of the 1.75 * 0.25 kgm
justed to match the working sensing surface of proximity
conditions. switch (3). Then tighten the bolts
to hold the plate in position.
4. After adjusting, start the engine

and operate the lift arm control
lever. Check that the lever is au-
tomatically returned to HOLD
when the bucket reaches the
desired height.
- 54 - W-04284
ADJUSTING BUCKET BUCKET LEVEL INDICATOR

POSiTlONER (A) and (B) at the top rear of the
Lower the bucket to the ground 3. Loosen two nuts (5) and to make bucket are the level indicators, so
and adjust the bucket to the a clearance of 3 to 5 mm be- the bucket angle can be checked
desired digging angle. Set the tween angle (2) and the sensing during operations.
bucket control lever at HOLD, surface of proximity switch (3).
stop the engine and adjust as Then tighten the nuts to hold in
follows. position.
Loosen two bolts (I) and adjust Ir Tightening torque:
the mounting bracket (4) of the 1.75 2 0.25 kgm
proximity switch so that the rear
tip of angle (2) is in line with the
center of the sensing surface of
proximity switch (3). Then tighten
the bolts to hold the bracket in
position. A: Parallel with cutting edge
B: 90” to cutting edge
4. After adjusting, start the engine

and raise the lift arm. Operate the
bucket control lever to the DUMP
position, then operate it to the
TILT position and check that the
bucket control lever is automati-
cally returned to HOLD when the
bucket reaches the desired angle.
W-04285 - 55 -
HANDLING THE TIRES
HANDLING THE TIRES

PRECAUTIONS WHEN PRECAUTIONS WHEN DRIVING
HANDLING TIRES MACHINE 0 Follow the regulations related to
If the following defects are found When the machine travels at this machine, and drive carefully.
in tires, for safety reasons the tire high speed for a long distance, the l The most suitable tire pressure,
should be replaced with a new tire. tires become extremely hot. This travel speed, or tire type differ ac-
Bead wire is broken or bent, or causes early wear of the tires, so it cording to the condition of the
the tire is greatly deformed. should be avoided as far as possible. travel surface. Contact your
Wear is excessive and the car- If the machine must be driven for a Komatsu distributor or tire dealer
cass ply (excluding breaker) is ex- long distance, take the following for information.
posed for more than l/4 of the precautions.
circumference.
Damage to the carcass exceeds Ambient Max. travel
Traveling time and breaking time
1 I3 of the tire width. temperature (“C) speed (km/h)
Tire layers are separated. Repeat

3n
_”
Radial cracks reach the carcass. I 1 13 kmor40’ (3H)
Deformation or damage which

makes the tire unsuitable for use. I 25
Travel
13 kmor35’
Travel
(3H)
28
Tread 13 kmor25’ (3H)
Travel Break Repeat
25
15 kmor35’ (3H)
Breakers
SIdewalls Travel Break Repeat
28 I
15 kmor30’ (3H)
Travel
28
18 kmor40’ (3H)
Beads
(Air pressure: 5.25 kg/cm21
- 56 - W-04286
HANDLING THE TIRES
TIRE PRESSURE
a When traveling with standard Measure the tire pressure before +r Stockpile operations mean the
tires L-5 on a paved road surface, starting operations, when the tires loading of sand and other loose
use the table as a guide. are cool. materials.
l L-4 tires are suitable as tires for If the inflation pressure is too
driving on roads, so contact your low, it causes overload on the tires; f Deflection ratio = HH-h xl00
Komatsu distributor or tire dealer. if the inflation pressure is too high,
l Check the tire pressure before the tire may be cut or may burst
starting, when the tire is cool. under shock. Therefore adjust the
l When the machine is stopped, inflation pressure to the values in
check the tires and all other parts the following table. As a guide for visual checks, the
for abnormalities, and check the deflection ratio (deflection/free
oil and coolant levels. height) of the front tire should be
l Always travel with the bucket Inflating tires as follows.
empty. Normal loading and carrying
l Never put calcium chloride or dry operations: approx. 10 - 15%
ballast in the tires when traveling. Digging operations (rear
wheels off ground):
approx. 20 - 25%
Connect the air charge hose to

air pickup (I) to inflate the tires.
- 57 -
HANDLING THE TIRES
* When checking the tire pressure, l For operations on normal road surfaces, rock digging operations: ..
check also for small cracks and High end of range in air pressure chart
damage, and for wire or small l Stockpile operations on soft ground: . . . . . ...
pieces of metal which may cause Average pressure in air pressure chart
punctures. Check also for abnor- l Operations on sand (operations not using much digging force) ..
mal wear. Low end of range in air pressure chart
* Operating costs can be reduced If the deflection of the tire is excessive, raise the inflation pressure within
and tire life increased by keeping the limits given in the table to give a suitable deflection (see deflection
the operating area in good condi- ratio).
tion and free from fallen rocks.
Inflation pressure (kg/cm’)

Tire size
(pattern)
Pb
rating
01
Free height
H Soft ground
(sandy ground)
Normal road
When shipped
from factory
Stockpile Digging. Stockpile Digging
(mm)
45165 -45 4.25 - 4.75 - 4.75 - 4.75 -
(L-5 Rock) 38 679 4.75 5.25 5.25 5.25
1 ,
45165 -45 Front tire: 5.25
(If equipped) 46 679 4.25 - 4.75 - 4.75 -
(L-5 Rock) 4.75 5.25 5.25
Rear tire: 5.25
45165 -45 4.25 - 4.74 - 4.75 - 4.75 -

(L-5 Rock) 5O 679 4.75 5.25 5.25 5.25
- 58 - W-04288
TOWING
TOWING
TOWING THE MACHINE
This machine must not be towed When engine can be used. When engine cannot be used.
except in emergencies. When l Always keep the engine running l No lubrication oil flows in the
towing the machine, take the follow- when towing the machine, so transmission, so disconnect the
ing precautions. that the steering and braking can front and rear drive shafts before
be used. moving the machine.
a If there is a failure in the brake 0 The steering cannot be used, so

line, the brakes cannot be disconnect the steering cylinder
used, so be extremely careful and steering linkage.
when towing.
-k The machine should be towed
only to the nearest place for in-
spection and maintenance. Do
not tow the machine for long
distances.
If leakage in the air circuit has
caused the pressure inside the air
tank to drop, the parking brake
will be applied. When towing the
machine, release the parking
brake.
ww-01304 - 59 -
TOWING
RELEASING PARKING BRAKE

(When no air is in air tank.)
1. Remove air charge socket (I 1 in- Remove parking brake switch (2) 4. Push the end of the hose on the
stalled on the front left of the and adapter (3) installed to the tire valve, and air will be supplied
rear frame. outlet side of the parking brake to the brake chamber to release
solenoid valve, and install the the brake.
socket removed in Step 1 in their 5. When the parking brake is
place. released, remove the air charge
Install the air charge hose for the hose. Tow the machine immedi-
tire to the air charge socket. ately to a safe place.
A If there is a failure in the air A Stop the machine on a flat sur-

circuit, the brakes cannot be face when releasing the park-
used. This is dangerous, so ing brake, and check that the
always tow the machine at low surroundings are safe. In emer-
speed. Keep the engine running gencies or when the parking
so that the steering can be brake must be released on a
used. hill, block the tires carefully
before releasing the brake.
* Contact your Komatsu distributor

To chamber I’
for details.
- 60 - ww -02050
TRANSPORTATION
TRANSPORTATION
When transporting this machine, it is necessary to disassemble it for

transportation.
Contact your Komatsu distributor for details of disassembly, trans-
portation and assembly after transportation.
W-02051 -61 -
COLD WEATHER OPERATION

PREPARATION FOR LOW
TEMPERATURE l Add antifreeze in the cooling + Cautions for using antifreeze
l Change lubrication oil by that water I) Permanent type antifreeze shall
with prescribed viscosity. When deciding the ratio of anti- be used.
l Fuel of low pour point shall be freeze to water, check the lowest 2) Soft water (ex: city water) shall
used. ASTM D975 No. 1 diesel temperature in the past, and be used as mixing water.
fuel should be used at at- decide from the mixing rate table 3) Cooling systems must be thor-
mospheric temperature lower given below. oughly flushed before filling with
than - 10°C. It is actually better to estimate a antifreeze mixture.
temperature about 10°C lower 4) When the climate becomes
when deciding the mixing rate. warmer so that antifreeze (with-
out corrosion inhibitor) is not
Mixing rate of water and antifreeze needed, replace by clean water
(ex: city water) after perfectly
Min. cleaning the cooling system.
atmospheric
A Take
temperature - 5 -10 -15 -20 -25 -30
(“C) care for fire as antifreeze
Amount of is inflammable.
antifreeze 73 95 114 130 146 158.5
(Q)
Amount of * When operating the machine at
water(Q) 244 222 203 187 171 158.5
temperatures below - 2O”C,
special equipment is needed.
Coolant capacity: 3 17 R Contact your Komatsu distributor
for details.
- 62 - W-04289
Care in using antifreeze

Use a Permanent Antifreeze * Where no permanent antifreeze * Measure specific gravity of fluid
(ethylene glycol mixed with corro- is available, an ethylene glycol an- and obtain rate of charge from
sion inhibitor, antifoam agent, etc.) tifreeze without corrosion inhibi- the following conversion table:
meeting the standard requirements tor may be used only for the cold
as shown below. With permanent season. In this case, coolant
antifreeze, no change of coolant is must be changed two times a >
required for a year. If it is doubtful year (at the beginning and at the
that an available antifreeze meets end of the cold season).
the standard requirements, ask the * Do not mix an antifreeze with
supplier of that antifreeze for one of different brand.
information. * Absolutely avoid using any water
Standard requirements for perma- leak preventing agent irrespective
nent antifreeze of whether it is used indepen- + When electrolyte level is low, add
- SAE . . . . . J1034 dently or mixed with an distilled water in the morning
. FEDERAL STANDARD antifreeze. before work instead of after the
~................ O-A-548D day’s work. This is to prevent
* Never use any antifreeze made l Battery fluid from freezing at night.
from alcohol which may be a As ambient temperature drops,
cause of engine trouble. battery capacity will drop, and A To avoid gas explosions, do not
electrolyte may sometimes bring fire or sparks near the
freeze if battery charge is low. battery.
Maintain battery at a charge level
of approx. 100% and insulate it A If the electrolyte gets on your
against cold temperature so that skin or clothes, immediately
machine can be readily started wash with plenty of clean
the next morning. water.
W-04086 - 63 -
STARTING IN COLD
WEATHER 2. Turn starting switch key (2) to
STARTING BY AUTOMATIC ON position.
PRIMING SYSTEM (APS)
When the ambient temperature
drops and it is difficult to start the
engine normally, use the following
starting procedure.
3. Keep fuel cut-off switch (3) in

OFF position (pull forward). Put
1. Open fuel valve (1) of the au-

tomatic priming system.
Sr Keep fuel valve (I) open when
the temperature drops during the
season the APS is used.
- 64 - w-04290
4. Put fuel cut-off switch (3) in ON * When the engine cooling water When the pre-heat monitor is still
position. temperature is over 13”C, if the illuminated and the starting
(When releasing the switch, it preheat switch is returned to switch is put in START position,
will return to ON position.) AUTO, the preheating monitor the glow plug will get wet, and
5. When preheater switch (4) is put will go out and automatic pre- there will be no ignition, so be
in the ON position, the pre-heat heating cannot be carried out. careful of starting problems.
monitor will light and automatic If normal starting is difficult, use When starting, and the starting
pre-heating will start. the procedure given in “Starting motor is rotating, the monitor will
* If the pre-heating monitor lights, using manual preheating” to start start to flash. If the flashing
return the preheater switch to the engine. stops after the engine starts,
AUTO position. (When releasing 6. Depress the accelerator pedal (5) there is nothing wrong.
the switch, it will return to AUTO about half way. Do not continue cranking the
position.) 7. Pre-heating finishes in about 80 engine for more than 20 seconds.
seconds. The pre-heating monitor
lamp will stop illuminating so turn
starting switch key (2) to START
position to start.
W-02889
- 65 -
If starting, return key of starting * After starting the engine, when * The standard specification ma-
switch (I ) to ON position. the water temperature reaches chine is designed to work in am-
(When releasing the key, it will about 20°C. the after-heating is bient temperature from -20°C
automatically return to ON.) automatically cancelled and the to 4o”c.
after-heating monitor lamp goes
OFF
out. The time taken for the after-
heating lamp to go out depends
on the ambient temperature.
Time taken after starting

Ambient
engine until after-heating
temperature
monitor goes out
If the engine does not start

through the steps specified
above, turn key of the starting
switch to OFF position and * If a work operation starts with
repeat Steps 2 to 8 at an interval forgetting to turn preheater
of approx. 2 minutes. switch to OFF position, the ex-
After starting the engine, when haust color will become bad, the
the after-heating monitor lamp horsepower will drop, and the life
goes out, turn preheating switch of the glow plug will be short-
(4) to the OFF position. ened, therefore, always be sure
to put preheater switch in OFF
position.
* Do not run engine rpm higher
than middle speed rpm.
- 66 - W-02890 -A
STARTING USING MANUAL CAUTIONS AFTER

PREHEATING COMPLETION OF WORK
When the engine water tempera- 1. Mud and water on the machine 2. Drain water collected in air tank
ture is above 13”C, automatic pre- body should be completely and fuel system so that such
heating cannot be carried out. removed. water may be frozen at night.
(When the preheat switch is turned Park the machine on concrete or 3. As battery capacity drops at low
to AUTO, the preheating monitor hard ground. If this is impossible, ambient temperature, cover the
lamp goes out.) If it is difficult to park the machine on wooden battery or remove it from the ma-
start the engine, use the following boards. This will prevent the ac- chine to be kept warm at night.
procedure. cessories from freezing to the
1) Put starting switch key to ON ground thereby preventing ma-
position. chine movement the next morn-
2) Keep the preheater switch in ing. Particular attention should be
ON position with hand until given to water drops collected on
the preheating monitor goes the surface of the hydraulic cylin-
off. der piston rods. Such droplets
3) As soon as light goes off, must be fully wiped off because
quickly return starting switch if water is frozen to the rod when
to START position, and start the cylinder is utilized, the cylin-
engine. der oil seals may be damaged.
4) After starting, put preheater
switch in OFF position.
A There is a danger of explosion

when using a starting aid liquid
for starting the engine, there-
fore, never use it.
ww-02891 - 67 -
AFTER COLD WEATHER

When weather becomes warm,
perform the following without fail:
l Replace lubricating oils for vari-
ous units with the ones specified
for warm-weather use.
l Drain antifreeze coolant (except
permanent type), flush the inside
of cooling system completely,
and fill with clean soft water
(such as city water).
l As the APS (Automatic Priming
System) becomes useless (at
15°C or above), be sure to close
the fuel valve for the APS.
- 68 - w-04291
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
Proper lubrication and maintenance assure trouble-free operation and

long machine life. Time and money spent for scheduled periodic mainte-
nance will be amply compensated by prolonged machine operation and re-
duced operating cost.
All hourly figures given in the following descriptions are based on service
meter readings. In practice, however, it is recommended to rearrange all of
them into units of days, weeks and months to make the maintenance
schedule more convenient. Under rough job site or operating conditions, it is
necessary to somewhat shorten the maintenance intervals stated in this
manual.
W-01316 - 69 -
BLEEDING AIR FROM CIRCUIT

BLEEDING AIR FROM POC BLEEDING AIR FROM BRAKE
CIRCUIT HYDRAULIC CIRCUIT
Remove piping of POC circuit, or
when removing strainer, after
assembling, bleed air from inside of
the circuit as follows:
1) Put bucket control lever in TILT
position and boom control lever
in FLOAT position, and after
cylinder reaches stroke end, keep
in that position for one minute.
2) Put bucket control lever in DUMP
position and boom control lever After removing piping of brake 3. Repeat until air bubbles stop
in RAISE position, and after cylin- hydraulic circuit, bleed air from coming out of air bleeder plug
der reaches stroke end, keep in inside of the circuit as follows: (A). After bleeding air, close plug
that position for one minute. * After assembling the piping,_ be and fit cap.
+ For details, contact your sure to check that the connectors * Bleed air at 4 locations.
Komatsu Distribor. are not loose. * After bleeding air, check the oil
1. Remove the cap of air bleeder level in the brake oil tank. If it is
plug (A). insufficient, add engine oil.
2. Depress brake pedal, loosen air
bleeder plug (A) about 3/4 of a A Never use the vegetable oil.
turn and after closing plug,
release pedal.
- 70 - ww-02054
BLEEDING AIR FROM PISTON

PUMP * The case drain hoses (x 3) for
each pump are connected to
block (3). but loosen only the
connector of case drain hose (2)
connected to the top of the
block. There is no need to loosen
the connectors of the other two
case drain hoses.
3. Turn knob (4) of the hydraulic
tank pressurizing valve to the
left, and adjust so that the gauge
indicator reads approx. 0.01
When changing the oil in the hy- Loosen plug (1) on top of the kg/cm2.
draulic tank, or removing the piston tube at the suction side of the A If the pressure of the pressuriz-
pump, or removing the piping of the piston pump. There is one plug ing valve is too high, oil may
piston pump, bleed the air from the for each pump, so loosen all spurt out from plug (1) and
piston pump in the following way plugs (3 places). hose (21, so adjust the pressure
after assembling. Loosen the connector at block carefully.
* Before bleeding the air from the (3) side of case drain hose (2) of 4. Turn valve (5) to the right to
piston pump, check that the hy- the piston pump. open it, and pressurize the oil
draulic oil in the hydraulic tank is inside the hydraulic tank.
filled to the specified level.
ww-02055 -71 -
BLEEDING AIR FROM

HYDRAULIC CIRCUIT
5. Continue until oil flows out from After bleeding air from piston * If the engine is run at high
plug (I) (3 places) and the pump, bleed air from hydraulic speed at first, or if the cylinder
connector of hose (2). When the circuit. is moved to the end of its
air has been completely bled, After replacing oil, filter element stroke, the air in the cylinder
tighten plug (I) (3 places) and or strainer, bleed the air from the may damage the piston pack-
the connector of hose (2). circuit. ing, etc.
6. Close valve (5), and set the read- To bleed the air from the hydrau- 4. After bleeding the air, tighten
ing of the gauge of the pressuriz- lic cylinders or hydraulic piping, air bleeding plug (I 1.
ing valve to “0”. run the engine at low idling and + Tightening torque of the plug
7. Check the oil level and add oil if do as follows. (I): 1.15 20.15 kgm
necessary. 1. Operate each hydraulic cylin-
ders (of steering, bucket and
A the
If the air is not bled completely,
piston pump may be dam-
lift arm) 4 to 5 times, stopping
100 mm from stroke end.
aged, so always carry out the 2. Next, operate each cylinder 3
air bleeding operation to 4 times to the end of its
correctly. stroke, then stop the engine
and loosen air bleeding plug
When pressurizing the tank, the (1) of the hydraulic tank to
tank cannot be pressurized if the bleed the air.
oil filler cap of the hydraulic tank 3. Increase the engine speed,
is not tightened. and repeat step 2 to bleed the
For details, contact your air until no more bubbles
Komatsu distributor. come out from plug (1).
- 72 - w-04292
PERIODICAL REPLACEMENT OF SAFETY PARTS
PERIODICAL REPLACEMENT OF SAFETY PARTS

The users of our machine should carry out periodi-
cal maintenance in order to ensure the working and op-
eration safety. Those parts, as listed on the right,
which are closely connected with safety, must be re-
placed periodically so that the highest safety standard
can be maintained.
These parts with the passage of time have a great
tendency to deteriorate in quality, and to wear ratter
soar. Furthermore, their defective condition is difficult
to detect during periodical maintenance. These parts
I Safety parts for
periodicreplacement
Replacement Remarks
interval I
must, therefore, be replaced with new ones after a pre-

determined service period even though there is no ap- 2 Rubberpartsfor powercluster Everyyear Replacewith
repairkit
parent abnormality.
Packings, seals, O-rings of
It goes without saying that if any abnormality 3 Every 2 years
steering cylinder
should be found, these parts must be replaced or
4 ) Rubber hose for steering cylinder) Every 2 years)
repaired even before the predetermined period expires.
The periodical replacement is completely different 5 ) Fuel hose 1Every~2 vearsr ~ ~
from the replacement due to the claim against the Replace with
6 Rubber parts for treadle valve Every year
repair kit
guarantee by the manufacturer, so they must be treat-
Rubber parts for parking Replace with
7 Every year
ed separately. brake spring cylinder repair kit
Replace with
8 Rubber parts for slack adjuster Every year
repair kit
W-02550 -A - 73 -
MAINTENANCE TABLE
MAINTENANCE TABLE
NO. ITEM SERVICE PAGE
a 1 Walk-around check 39
onitor panel Check 39
c I Coolant Check and supply 39
d ) Engine oil pan Check and supply 40
Drain water and

h Air tank 42
sediment
I ,
i Brake oil tank Check and supply 43
j Water separator Check 43
k / Parking brake Check function 44
I ) Foot brake Check functicn 44
m Horn Check function 44
n Lamps Check function 44
- 74 - w-04293
MAINTENANCE TABLE
No. ITEM SERVICE PAGE
-2 Dump cylinder pin Lubricate 2 points 81
-3 Tilt lever pin Lubricate 1 point 81
-4 Bucket link pin Lubricate 1 point 81
-5 Lift cylinder pin Lubricate 4 points 82
-6 Steering cylinder pin Lubricate 4 points 82
-7 Rear axle pivot pin Lubricate 3 points 82
INITIAL 250 HOURS SERVICE
a Fuel filter Replace cartridge 83
b Transmission oil filter Replace element 83
c 1 Enginevalve clearance ( Check andadjust 1 83
I EVERY 250 HOURS SERVICE I
~~~
Air conditioner compressor
d Alternator belt Check tension

. 86
w-04294 - 75 -
MAINTENANCE TABLE
No. ITEM SERVICE PAGE No. ITEM I SERVICE PAGE
I (EVERY 1000 HOURS SERVICE) I h I Turbocharger 1Check and clean [I 01
-4
-5
-6
JR ear drive shaft
1Upper drive shaft
Parking brake linkage

) Lubricate3
1 Lubricate
points
2 points
Lubricate 6 points
1 92
1 93
93
1 Alternator and starting motor
Bucket hinge pin and Change oil

-7 Damper Lubricate 1 point 93 102
’ bucket link pin
Torque converter mount
-8 Lubricate 1 point 93 m Hydraulic tank strainer Clean 102
trunnion
I I 1
1 Check Replace
d 1Turboch arger various fasteners and retighten 1 93 n Air dryer
internal parts
103
ROPS canopy Check and retighten 94 EVERY 4000 HOURS SERVICE
f I Corrosion resistor Replace cartridge 94 a Water pump Check 104
I EVERY 2000 HOURS SERVICE I b Air compressor Check and adjust 104
Change oil and

a
I
Hydraulic tank and filter
I
replace element
96
c I Fan pulley and tension pulley Check 104
b Axle (Front and rear) Change oil 97 d / Engine vibration damper Check 104
C Air conditioner filter Replace element 99
Hydraulic tank breather Replace element 99 I WHEN REQUIRED I

POC (Pilot Operated Control) Clean
e Clean 100 a 1 Cooling system 105
circuit strainer
I I
Check, clean or re-
f Engine breather Clean element 100 b Air cleaner element 107
place when required
9 Turbocharger rotor Check play 101 C Transmission Check and supply 110
- 76 - w-04295
MAINTENANCE TABLE
NO. ITEM SERVICE PAGE
d Radiator fins Clean 111
e I Axle oil Check and supply 111
f Lubricating 112
-1 Work equipment control valve Lubricate 2 points 112

linkage ,,,,.,,,,
-
-2 Accelerator pedal linkage Lubricate 2 points 112
-3 Steering column Lubricate 1 point 113
g Bucket teeth Replace 113
h / Air conditioner Check 114
I Condenser of air conditioner Check and clean 115
i Window washer Check and supply 115
k Axle case breather Clean 116
I Glow plug of APS Check 116
m APS fuel filter Replace cartridge 117
n Water separator Drain water 117
W-04296 - 77 -
OIL FILLER AND LEVEL GAUGE POSITIONS
OIL FILLER AND LEVEL GAUGE POSITIONS

1. Engine oil pan level gauge and 6. Cooling water inlet 10. Hydraulic tank drain valve
oil filler 7. Hydraulic tank oil filler 1 1. Rear axle drain plug
2. Cooling water drain plug 8. Hydraulic tank oil level gauge 12. Fuel tank drain valve
3. Engine oil pan drain plug 9. Front axle drain plug 13. Fuel tank oil filler
4. Final drive case drain plug
5. Final drive case level plug
- 78 -
EVERY 50 HOURS SERVICE
CHECK BEFORE EVERY 50 HOURS

STARTING SERVICE
See the section on CHECK a. FUEL TANK b. TIRE
BEFORE STARTING afore- Measure the inflation pressure
mentioned. before operations when the tires are
cool. (Refer to HANDLING THE
TIRES.)
Loosen valve (I) on the right side

of the tank so that the precipitation
and mixed water will be drained in
accompaniment with fuel.
W-02067 - 79 -
EVERY 100 HOURS SERVICE * Maintenance for every 50 hours should be car-
ried out at the same time.
a. HYDRAULIC TANK b. AIR CONDITIONER FILTER
1. Lower the bucket horizontally to * The type of lubricant used If the air conditioner has been
the ground and stop the engine. depends on the ambient used, the air filter should be cleaned.
Wait for 5 minutes, then check temperature. Select according to sr Stop the air conditioner before
sight gauge (G). The oil should be the table “FUEL, COOLANT AND cleaning the element.
visible in sight gauge (G). LUBRICANTS”. 1. Open the cover located on the
2. Add engine oil from oil filler IF), if behind of the operator’s seat.
necessary. A When removing the cap, turn it 2. Loosen screw (1) of holder hold-
slowly to relieve inner ing the filter element, pull out ele-
oressure. ment (2) and clean it.
- 80 - w-04297
c. LUBRICATING
Apply grease to the grease fit-
tings shown by arrows.
1 Lift arm pivot pin (2 points) 4. Bucket link pin (1 point)
2. Dump cylinder pin (2 points)
3. Tilt lever pin (I point)
3. Align the direction of the arrows

and assemble.
,, ,, ,,,., ,, ,,,,,, ,,,,,,,,,
* Direct dry compressed air (less

than 7 kg/cm? to element from
inside along its folds, then direct
it from outside along its folds and
again from inside, and check
element.
A When using compressed air,

wear safety glasses and other
things required to maintain
safety.
W-04298 -81 -
(4 points) 7. Rear axle pivot pin (3 points)

5. Lift cylinder pin (4 points) 6. Steering cylinder pin
w-04299
- 82 -
INITIAL 250 HOURS SERVICE
INITIAL 250 HOURS EVERY 250 HOURS

SERVICE SERVICE
Perform the following mainte- a. WHEEL HUB NUTS b. ENGINE OIL PAN AND FILTER
nance after running the machine
for the first 250 hours.
a. FUEL FILTER
b. TRANSMISSION OIL FILTER
c. ENGINE VALVE CLEARANCE
For details of the method of
replacing or maintaining, see the
section on EVERY 500 HOURS
AND 2000 HOURS SERVICE.
If wheel hub nuts (I) are loose, 1. Open the engine side cover on
tire wear will be increased ands acci- the left side of the machine, and
dents may be caused. If any hub apply open lock.
nuts are loose, tighten them to the 2. Loosen drain plug (1) on the left
specified tightening torque. side of the machine to drain the
t Tightening torque: oil, and tighten the drain plug
94.5 * 10.5 kgm again after draining the oil.
+ If any wheel nut is broken, replace * When draining the oil, fit the sup-
all nuts for that wheel. plied vinyl tube to the drain ports
* Always rotate in the direction of of the drain plug to prevent the
tightening when checking for oil from spraying out.
loose nuts.
- 83 -
Refill capacity: 64 Q
The type of lubricant used
ture. Select according to the
table “FUEL, COOLANT AND
LUBRICANTS”.
Be sure to fit a genuine Komatsu
cartridge.
Replace once every 6 months,
regardless of the number of
3. Using a filter wrench, remove car- 5. After replacing the cartridge, hours operated.
tridges (2) (3 pieces) of the pour in the specified quantity of If filter cartridges (2) are removed
engine oil filter by turning it engine oil from oil filler (F). immediately after stopping the
counterclockwise. 6. After pouring in oil, run the engine, oil will spill. Wait at least
4. Apply a dab of oil to the gasket engine for several minutes, then IO minutes after stopping the
of the new cartridge. once again check the oil level and engine before replacing the filter
* After the gasket contacts the ensure that it is correct. cartridge.
seal face, tighten it up by hand 7 Close the engine side cover. Use API category CD class oil. If
2/3 of a turn. CC class oil must be used,
change the oil and replace the oil
filter at half the usual interval
(I 25 hours).
- 84 - W-02895
c. AIR CONDITIONER
COMPRESSOR BELT
1. The belt tension should normally 2. To adjust the belt tension, loosen * When adjusting the V-belt, do
deflect by about 10 mm when bolts (I) and lock nut (31, and not attempt to push the compres-
pressed with the finger at a point rotate adjusting bolt (2). sor directly with a bar or the like,
midway between the air condi- 3. After adjustment, tighten bolts but use a wood pad to prevent
tioner compressor pulley and the (1) and lock nut (3) securely. damage to the core.
drive pulley (approx. 6 kg). * After operating the machine for t Check each pulley for damage,
one hour with a newly exchanged and V-grooves and V-belt for
V-belt, test and adjust the V-belt wear. Particularly, check whether
again. V-belt is in contact with bottom
of V-groove through wear.
* Replace belt if it has stretched,
leaving no allowance for
adjustment, or if there is a cut or
crack on belt.
W-02073 - 85 -
d. ALTERNATOR BELT
1. The belt tension should normally 2. To adjust the belt tension, loosen When adjusting the V-belt, do
deflect by about 9 mm when bolt (I 1 and nut (2) and shift alter- not attempt to push alternator
pressed with the finger at a point nator (3) slightly. (3) directly with a bar or the like,
midway between the alternator 3. After adjustment, tighten bolt (I 1 but use a wood pad to prevent
pulley and the drive pulley and nut (2) securely. damage to the core.
(approx. 6 kg). Check each pulley for damage,
* After operating the machine for and V-grooves and V-belt for
A Alternator pulley one hour with a newly exchanged wear. Particularly, check whether
V-belt, test and adjust the V-belt V-belt is in contact with bottom
again. of V-groove through wear.
r
\, 1 Replace belt if it has stretched,
9mm
%T
w
leaving no allowance for ad-
justment, or if there is a cut or
Drive shaft pulley
crack on belt.
- 86 - w-02074
b. TRANSMISSION OIL FILTER c. FAN BELT

Check the V-belt and when the
following conditions exist, exchange
the V-belt:
When the V-belt makes contact
with the bottom of the groove in
each pulley.
When cracking and peeling of
the V-belt occurs.
For details of the replacement
procedure, refer to ADJUST-
MENT (replacement of fan belt
1. Loosen the bolt and open the Be careful not to apply excessive and adjustment of auto
side panel. torque to center bolt (3). tensioner).
2. Remove drain plugs (1) (6 Tightening torque: An auto tensioner is installed, so
pieces) at the bottom of the filter 7 5.5 +- 1.5 kgm it is unnecessary to adjust the fan
case, and drain the oil. After Run the engine for a short time at belt.
draining the oil, tighten the plug. idling speed, then stop the
3. Hold case (2) and loosen center engine. Check that the oil is at
bolt (3), then remove case (2). the specified level (for details,
4. Remove the element, and clean see WHEN REQUIRED).
the inside of the case. Assemble Use a genuine Komatsu element.
a new element, then install the Replace the filter gasket and O-
case. rings with new parts. Coat the
gasket and O-rings with clean
engine oil before installing.
- 88 - W-04302
d. LUBRICATING e. AIR DRYER

Apply grease to the grease fitting If the air dryer is installed as an
shown by arrow. option, carry out the following in-
spection, and if there is any abnor-
1. Center drive shaft (3 points) 2. Fan pulley bearing (I point) mality, contact your Komatsu
distributor.
Open the air tank drain valve and
check that nothing is drained.
Note that if the temperature
around the tank is lower than
16”C, a small amount of water
may be collected in the drain.
Check that there is no abnormal
inclusion of oil in the water drain
from the exhaust port of the air
3. Tension pulley bearing (I point) dryer.
w-04303 - 89 -
EVERY 1000 HOURS SERVICE * Maintenance for every 50, 100. 250 and 500
hours should be carried out at the same time.
a. TRANSMISSION CASE AND

STRAINER
1. Remove drain plug (I 1 and loosen 2. Loosen drain plugs (3) (6 pieces) 3. Remove bolt (4) and cover (51,
plug (2) to drain oil. After of transmission oil filter to drain then remove spring (6) together
draining off the oii, tighten up oil. After draining off the oil, with strainer (7).
drain plugs. tighten up drain plugs (3). 4. Remove all dirt from the surface
* After loosening drain plug (21, of strainer (71, then wash in clean
pull out the plug slowly to light oil. If strainer (7) is
prevent the oil spouting out. damaged, replace wifh a new
part.
5. Install spring (6) and strainer (7)
in cover (5). Replace the O-ring
of the cover with a new part,
then install the cover.
- 90 - W-02080
b. TRANSMISSION CASE
BREATHER
Refill capacity: 140 !2 Remove all mud and dirt from

The type of lubricant used around the breather, then remove
6. Pour in the specified amount of depends on the ambient the breather. Put in cleaning fluid
engine oil from oil filler (F). temperature. Select according to and clean the breather.
7. After refilling, check the oil level the table “FUEL, COOLANT AND
and ensure that it is correct. LUBRICANTS”.
(Refer to WHEN REQUIRED.) Check for oil leak at transmission
case and filter.
Make an oil level check before
starting engine or 60 minutes or
more after the engine is stopped.
If oil remains at various portions,
the correct oil level cannot be
measured.
W-02081-A -91 -
c. LUBRICATING
Apply grease to the grease fit-
tings shown by arrows.
1. Center hinge pin (2 points) 2. Drive shaft center support 4. Rear drive shaft (3 points)
(I point)
3. Front drive shaft (3 points)
- 92 - W-02082
d. TURBOCHARGER VARIOUS
FASTEhiERS
5. Upper drive shaft (2 points) 6. Parking brake linkage (6 points) Any leaky joint connecting to the
engine exhaust pipe will cause a
lowering of oil pressure, resulting in
seizing of bearings.
Connect your Komatsu distribu-
tor for repairs, or check as follows.
Tighten if necessary.
Turbine housing mounting bolt
Tightening torque:
6.0 - 7.5 kgm
Blower housing clamping bolt
Tightening torque:
7. Damper (1 point) 0.9 - 1 .O kgm
8. Torque converter mount trunnion Turbocharger mounting bolt (for
(I point) securing the exhaust manifold
SWS?,Y,T”“‘
,,,,,
:; and turbine housing together)
,“:”
‘“;
A,:‘..
‘,,,:f
I-,,,,,,,
,:, : Tightening torque:
10.0 - 1 1.5 kgm
,, ,: ”
:
:‘, ,
,’ \
w-04304 - 93 -
e. ROPS CANOPY f. CORROSION RESISTOR

l Turbocharger oil feed pipe (inlet
line)
Tightening torque:
2.8 - 3.5 kgm
l Turbocharger oil feed pipe (out
line)
Tightening torque:
6.0 - 7.5 kgm
1. Loosen bolt, then remove cover. 1. Open the engine side over located
2. Check that there is no looseness at the right of the body and lock
in mounting bolts (1) of the open lock.
ROPS canopy. If any bolt is loose, 2. Close valve (I 1.
tighten it. 3. Using the filter wrench provided,
* Tightening torque: 280 * 30 remove cartridges (2) (2 pieces)
kgm by turning it counterclockwise.
3. Install cover. 4. Fit a new cartridge after applying
sr The tightening torque is large, so a dab of engine oil to the seal
a power wrench is needed when face.
tightening. Please request your
Komatsu distributor to carry out
this work.
- 94 - w-04305
* To fit the cartridge, put the seal

face in contact with head, then
screw it up by hand about l/2 to
3/4 of a turn. (Be careful not to
apply excessive torque.)
5. After replacement, open valve
(I).
* Be sure to use a genuine
Komatsu cartridge.
* After replacing the cartridge,
start up the engine and check the
filter seal face for possible oil
leakage.
W-04306 - 95 -
EVERY 2000 HOURS SERVICE * Maintenance for every 50, 100, 250, 500 and 1000
hours should be carried out at the same time.
a. HYDRAULIC TANK AND

FILTER
1. Lower the bucket horizontally to t After loosing drain valve (21, pull 5. Remove spring (6) and bypass
the ground and apply the parking it out slowly to drain oil. valve (7), then remove element
brake, then stop the engine. 4. Remove mounting bolt (5) of the (8).
2. Remove the cap of oil filler (F) filter cover (41, then remove * Check that there is no foreign
and air vent plug (1) on filter case. cover (4). matter inside the tank before
A When removing the cap, turn it cleaning it.
slowly to relieve inner A The cover is pushed by a 6. Install a new element, then install
pressure. spring, so hold the cover when bypass valve (71, spring (61, and
3. Remove drain plug (3) and loosen removing the bolts. cover (4).
drain valve (2) to drain oil. After If the O-ring of the cover is dam-
draining off the oil tighten up aged or deteriorated, replace it
them. with a new part.
- 96 - ww -02085
b. AXLE
A Never start the engine before
the air has been completely Front
bled from the piston pump. If
the engine is started without
the air being bled from the
piston pump, the piston pump
may be broken.
9. Bleed the air of hydraulic circuit,
refer to BLEEDING AIR FROM
HYDRAULIC CIRCUIT. Then
lower the bucket horizontally to
the ground and stop the engine.
10. Check the oil level and ensure
that is correct. (Refer to EVERY
* When installing the cover bolts, 100 HOURS SERVICE.)
push down the cover and tighten * The type of lubricant used
the bolts evenly. depends on the ambient tem-
7. Pour in the specified quantity of perature. Select according to
engine oil from filler (F). the table “FUEL, COOLANT
8. Bleed the air from the piston AND LUBRICANTS”.
pump. * Refill capacity: 550 II
For details of bleeding the air, sr Check that there is no oil leaking
refer to BLEEDING AIR FROM from the filter cover mount.
CIRCUIT (bleeding air from
piston pump).
w-04307 - 97 -
Remove front and rear oil filler 4. After draining the oil, clean drain
plugs (I), then remove drain plugs (21, (3) and (41, then install
plugs (2) to drain the oil. them.
Remove drain plug (3) to drain 5. Add oil to the specified level
the oil. After draining, tighten up through the oil filler ports (I) and
it. (5) of the axle housing and left
Stop the machine so that drain and right final drives.
plug (4) of the final drive is at the 6. Check the oil level and ensure
bottom. Remove oil filler plug (5) that is correct. (Refer to WHEN
and drain plug (41, and fit the REQUIRED.)
tube of attached tool in hole of
plug (4) and drain the oil.
- 98 - W-04308
c. AIR CONDITIONER FILTER d. HYDRAULIC TANK BREATHER
Use the same procedure to 1. Open the cover located on the 1. Remove cap of oil filler.
change the oil for the front and behind of the operator’s seat.
rear axles. 2. Loosen nut (1) holding the filter A When removing the cap, turn it
Refill capacity: 360 !Z(each axle) element, pull out element (2). slowly to relieve inner
The type of lubricant used 3. Install a new element and close pressure.
depends on the ambient tempera- the cover.
ture. Select according to the 2. Remove snap ring on breather
table “FUEL, COOLANT AND (I 1, then remove breather cap.
LUBRICANTS”.
w-04309 - 99 -
e. POC (Pilot Operated Control) f. ENGINE BREATHER

CIRCUIT STRAINER 1. Remove the breather pipes from
the cylinder blocks of the left and
right banks.
2. Check that there is no sludge
inside the pipes.
* If there is any sludge, replace the
pipe with a new part.
3. Replace filter element with a new 1. Loosen bolts (I) (3 pieces).

part, then install cap and snap 2. Remove strainer case and pull
ring. out the strainer, then wash strain-
Sr It is possible to replace the ele- er with clean diesel fuel.
ment with the breather installed 3. Install the strainer in the strainer
in the tank. However, if the case, and mount with bolts (I 1.
breather is removed, do not wrap 4. Bleed the air from the hydraulic
the taper thread of the breather oil circuit. (See Section on
with seal tape when assembling “BLEEDING AIR FROM
again, and be careful not to tight- CIRCUIT”.)
en too much.
- IOO- w-04310
g. TURBOCHARGER ROTOR PLAY h. TURBOCHARGER

Contact your Komatsu distribu- Excessive carbon or oil sludge ad- 4. Rotate the impeller by hand at
tor for checking, or proceed as hering to turbocharger blower im- least one turn at speed to check
follows: peller may lead to deterioration of that there is contact noise or
Remove air intake pipe from normal charger performance, and catching inside.
turbocharger. possible damage. Have turbocharger If the impeller does not turn
1. Axial play cleaned by Komatsu distributor. smoothly, contact your Komatsu
Check axial play by moving rotor 1. Remove the turbocharger oil filler distributor for repair or
in axial direction. pipe and drain pipe, then remove replacement.
Play: the intake air pipe connector and 5. If there is no abnormality, dry off
Standard 0.08 - 0.18 mm blower housing so that the the light oil with compressed air
2. Radial play blower impeller can be seen. after inspection, then add engine
Measure radial play by moving 2. Using light oil as a cleaning oil.
rotor holding both ends by hands agent, remove the carbon, sludge
in radial direction in parallel. and other dirt from the blower
Play: impeller. Do not use a wire brush
Standard 0.25 - 0.60 mm or other tool which may damage
f If the rotor is excessively soiled the impeller.
with dust or carbon or if any oil 3. Pour in light oil through the tur-
leakage caused by turbocharger bocharger oil filler and rotate the
trouble is noted, have the tur- blower impeller several times to
bocharger repaired by your wash out the sludge.
Komatsu distributor.
w-04311 - 101 -
i. ALTERNATOR AND STARTING I. BUCKET HINGE PIN AND m.HYDRAULIC TANK STRAINER
MOTOR BUCKET LINK PIN
As the hours of engine employ-
ment indicate that the brushes are
already worn out, you should re-
quest repair from a Komatsu
distributor.
They should be repaired every
1000 hours, if the machine is fre-
quently operated at night.
ENGINE VALVE CLEARANCE

Ask Komatsu distributor to 1. After removing plugs (1) and (21, When changing the oil in the hy-
check engine valve clearance be- refill gear oil (SAE140 GL-5) draulic tank, drain the oil from the
cause special tools should be used. from hole of plug (I) until new oil tank and clean the strainer.
comes out from grease fitting Loosen bolts (1) and (31, then
k. BRAKE DISC inside. remove covers (2) and (4).
Ask Komatsu distributor to * Amount of refill oil: Loosen bolt (51, remove strainer
check and repair brake disc. Approx. 0.278 cover (61, then remove strainer
(8) together with spring (7).
2. Install plugs (I 1 and (2). Remove any dirt from strainer
+ After removing bucket pin, be (81, then wash in clean light oil or
sure to refill with oil. flushing oil.
* Never use grease in place of gear If strainer (8) is broken, replace it
oil. with a new part.
- 102- w-04312
n. INTERNAL PART OF AIR

DRYER
If the air dryer is installed as an
_y
option, replace the following internal
r>i$: iJ parts of the air dryer:
Desiccant, oil filter, filter, and all
x
;:
/;_: ) :,-‘$ ~h”,“,:;atisreplaced.

Contact your Komatsu drstributor to
4. Install spring (7), strainer (8), and 5. Install covers (2) and (4).
cover (6). When doing this, look * Replace the O-rings of the
through the mounting hole of covers with new parts.
cover (4) to check that the strain-
er guide pin is fitted in the guide
hole.
* When installing cover (61, coat
the thread of bolt (5) with thread
tightener (LT-2) to prevent it
from coming loose. If bolt (5) be-
comes loose and drops out, it will
be sucked into the piston pump
and will damage the pump.
Tightening torque of bolt (5):
9 2 3.5 kgm
w-04313 - 103-
EVERY 4000 HOURS SERVICE * Maintenance for every 50, 100, 250, 500, 1000 and
2000 hours should be carried out at the same time.
a. WATER PUMP d. ENGINE VIBRATION DAMPER

Inspect the water pump for play Check decrease of damper fluid,
in the pulley, grease leakage and dent or out-of-flat. If there is any ab-
water leakage. normality, contact your Komatsu
If any fault is detected, ask distributor for repair.
Komatsu distributor to disassemble
and repair or replace.
b. AIR COMPRESSOR
Special tools are needed for test-
ing and adjusting, so ask your
Komatsu distributor to disassemble
and repair or replace.
c. FAN PULLEY AND TENSION

PULLEY
Check the pulley to see if there is
any leaking grease. If any abnormali-
ty is found, ask your Komatsu dis-
tributor to repair or replace it.
- 104- w-04314
WHEN REQUIRED
WHEN REQUIRED
a. CLEAN INSIDE OF COOLING
SYSTEM Corrosion resistor
l Clean the inside of the cooling
system, replace the antifreeze,
and replace the corrosion resis-
tor, according to the table.
l Change water after first parking
the machine on a level surface.
Stop the engine, tighten up corro-

sion resistor valve (I), and turn
cap (2) slowly until it comes off.
Cleaning inside of
Type of antifreeze Replacing corrosion Open drain valve (3) of the radia-
cooling system and
solution resistor
replacing antifreeze tor, valve (4) of the oil cooler and
Every 1000 hours and when valve (5) on the side of cylinder
Every year (autumn) or
cleaning the inside of the block to drain off the cooling
Permanent type antifreeze every 2000 hours whichever
cooling system and when
comes first water.
replacing antifreeze
After draining the cooling water,
Every 6 months (spring, Every 1000 hours and when
Other permanent type close up drain valves (31, (4) and
autumn) cleaning the inside of the
antifreeze of eltylene
Change antifreeze only cooling system and when (51, and pour in soft water (ex:
glycol base
in autumn replaceng antifreeze
city water) up to the vicinity of
Every year (autumn) or Every 1000 hours and when the water filler.
When not using antifreeze every 2000 hours whichever cleaning the inside of the
comes first cooling system
w-04315 - 105-
WHEN REQUIRED
Water filler Drain valves (radiator, oil cooler) Drain valve (cylinder block)
4. When the water reaches the 5. When the water becomes com- After cleaning, drain all the cool-
vicinity of the water filler, put the pletely clean, stop the engine, ing water, then close the drain
engine at low idling, open drain draining off the cooling water, valves (31, (4) and (51, and fill
valves (31, (4) and (51, then pass and close drain valves (3), (4) slowly with soft water.
water for 10 minutes through and (5). When the soft water comes up
the cooling system until clean 6. After draining the water, clean to near the radiator water filler
water comes out from drain with a cleaning agent. port, start the engine, and run at
valves (3), (4) and (5). * We recommend use of a low idling. Add soft water, open
* When doing this, adjust the Komatsu genuine cleaning agent. drain valves (3). (4) and (51, and
speed of filling and draining the For details of the cleaning continue to run water until clean
water so that the radiator is method, see the instructions colorless water comes out from
always full. given with the cleaning agent. the drain valves (31, (4) and (5).
When doing this, adjust the
speed of filling and draining the
water so that the radiator is
always full.
- 106 - h-04316
WHEN REQUIRED
b. CHECK, CLEAN AND REPLACE

9. When the water is completely Use city water for the cooling AIR CLEANER ELEMENT
clean, stop the engine and close water.
drain valves (3). (4) and (5). If river water, well water or Checking
10 Replace the corrosion resistor other such water supply must
cartridge with a new part, and be used, contact your Komatsu
open the corrosion resistor distributor.
valve (I 1. Do not use any alcohol base
* For details of replacement of antifreeze.
the corrosion resistor, see Be sure to replace the corrosion
EVERY 1000 HOURS SERVICE. resistor cartridge.
11. Add soft water until it overflows
from the water filler. A Do not remove the cap while
12. To remove the air in the cooling cooling water is hot. Hot water
water, run for 5 minutes at low may spout out.
idling, then for another 5 mi- When removing radiator cap, Whenever the red piston in dust
nutes at high idling. lift the lever to relieve inner indicator (I) appears, clean the air
When doing this, leave radiator pressure. cleaner outer element. Stop the
cap (2) off. engine when cleaning the element.
13. Stop the engine, wait for about
3 minutes, add soft water to
the specified level, then tighten
cap (2).
w-o.4317 - 107-
WHEN REQUIRED
Cleaning or replacing outer

element Ir Remove one seal from the outer
element. The number of times
the outer element has been
cleaned can be seen by the
number of removed seals.
* Check inner element mounting
nuts for looseness and, if neces-
sary, retighten.
* Replace seal washer (4) or wing
nut (2) if they are broken.
1. Remove wing nut (2) and outer + Replace the outer element which
element (3). has been cleaned 6 times repeat-
2. Clean the air cleaner body interior edly or used throughout a year.
and the removed cover. Replace the inner element at the
3. Clean and inspect the element. same time.
(See the item “Cleaning outer ele- * Replace both inner and outer ele-
ment” for cleaning procedure.) ments when the dust indicator
4. Install the cleaned element. red piston appears soon after in-
5. Push the dust indicator reset stalling the cleaned outer element
button to return the red piston to even though it has not been
the original position. cleaned 6 times.
- 108- W-04318
WHEN REQUIRED
Replacing inner element Cleaning outer element

1. First remove the outer element. The following methods require
2. Remove the inner element. With compressed air spare parts.
3. Place the cover over the air With water
intake part to prevent dust Dash city water (less than 3
entering. kg/cm? on element from inside
4. Clean the air cleaner body interi- along folds, then from outside and
or, then remove the cover from again from inside. Dry and check it.
the air intake port.
5. Fit a new inner element and tight- With cleaning agent
en it with nuts. For removing oils and fats as well
Install the outer element and the as carbon etc. attached on the ele-
cover. Push the dust indicator ment, the element may be cleaned
reset button. in lukewarm solution of mild deter-
Direct dry compressed air (less gent, then rinsed in clean water and
Do not attempt to reinstall a than 7 kg/cm? to element from left to drip dry.
cleaned inner element. inside along its folds, then direct it Drying can be speeded up by
from outside along its folds and blowing dried compressed air
A cleaner
Do not clean or replace the air
with the
again
element.
from inside, and check less than 7 kg/cm21 from the
inside to the outside of the
element
engine running. element.
A When using compressed air, Never
element.
attempt to heat the
wear safety glasses and other
things required to maintain Using warm water (about 40°C)
safety. instead of soapy water may also
be effective.
w-04319 - 109-
WHEN REQUIRED
c. CHECK AND REFILL

TRANSMISSION OIL
Carry out this procedure if there
is any sign of oil on the transmission
case, or if there is oil mixed with the
cooling water.
If small holes or thinner parts are * Stop the engine when checking
found on element when it is the oil level.
checked with an electric bulb * Make an oil level check before
after cleaning and drying, replace 1. Use sight gauge (G) to check the starting engine or 60 minutes or
the element. oil level. more after the engine is stopped.
Do not use element whose folds 2. If the oil level is not between the If oil remains at various portions,
or gasket or seal are damaged. top and bottom marks on the the correct oil level cannot be
When cleaning element, do not sight gauge, add engine oil measured.
hit it or beat it against something. through oil filler (F).
* The type of lubricant used A When
apply
checking the oil level,
the parking brake, and
ture. Select according to the lock the front and rear frames
table “FUEL, COOLANT AND with the safety bar and pin.
LUBRICANTS”.
- IlO- W-04320
WHEN REQUIRED
d. CLEAN RADIATOR FINS e. CHECK AND REFILL AXLE OIL

Carry out this procedure if there Carry out this procedure if there
is any mud or dirt seen stuck to the is any sign of oil on the axle case.
radiator.
Front
1. Loosen bolt (1) and remove * The rubber hose should be

radiator grille (2). checked at the same time. If the Remove oil level plug (I), and
2. Clean the radiator fins and oil hose is found to have cracks or check that the oil level reaches the
cooler fins clogged with mud, to be hardened by ageing, such bottom of the plug hole. If
dust and leaves with compressed hose should be replaced by new necessary, add oil through the hole
air. Steam or water may be used one. Further, loosened hose of plug (I 1.
instead of compressed air. clamp should also be checked.
w-04321
-lll-
WHEN REQUIRED
f. LUBRICATING
Apply grease to the grease
Rear fittings shown by arrows.
1. Work equipment control valve 2. Accelerator pedal linkage

linkage (2 points) (2 points)
If the work equipment control If the accelerator pedal is heavy
lever is heavy or does not move or does not return properly, apply
smoothly, apply grease. grease.
* The type of lubricant used

depends on the ambient
temperature. Select according to
the table “FUEL, COOLANT AND
LUBRICANTS”.
- 112- W-04322
WHEN REQUIRED
g. REPLACING BUCKET TEETH

If the bucket equipped with tip
tooth.
Replace the teeth before they
wear down as far as the adaptor.
3. Steering column (1 point)

If the play of the steering column
0
is heavy or does not return properly,
apply grease.
* When extracting pin (21, strike

the part (either the left or right
part) with a sharp object. This
will enable the pin to be extracted
1. Extract pin (2) fitted to the from the opposite side.
bucket and then remove tooth
(I). 2. Insert the new tooth (I) into the
adaptor (31, and insert pin (2)
partway as shown in the diagram.
Then drive it home by means of a
hammer.
W-04323 - 113-
WHEN REQUIRED
h. CHECK AIR CONDITIONER
Cooler
Normal Abnormal
No refrigerant :ondition
remp. of high, High pressure pipe is High pressure pipe is Almost no difference ir
Correct amount and low hot. warm. temperature between
xessure pipes Low pressure pipe is Low pressure pipe is high and low pressure
Lack of refrigerant
cold. cold. pipes.
Clear difference in Little dirrerence in
temperature temperature
jight glass Almost transparent. Bubbles are always Misty substance is

Any bubbles disappear flowing. Sometimes flowing.
Check refrigerant (gas) level if the engine speed is becomes transparent,
reaised or lowered. or shite bubbles
If the refrigerant level is too low,
appear.
the cooling effect is reduced. When
0
the cooler is being operated at high z_--
0
---
0
speed, air bubbles cannot usually be -_ -_- --.
- -----
0 0 --- = -z_
seen in the sight glass (inspection - - _=
_z - z- _- -
window) installed on the receiver on 0
-
the right side of the air cleaner.

If air bubbles are formed, the Connections Properly connected Some parts dirty with zt;;;arts very dirty
of pipes oil
refrigerant level is too low, so have
your dealer add refrigerant General condi- Coolant level correct, May be a leak some- Almost all coolant has
tion of cooler no abnormalities. where. Call service leaked out.
immediately.
Ready for use repair shop for Contact service repair
inspection, shop immediately.
-
- 114- w-04324
WHEN REQUIRED
i. CLEAN CONDENSER OF AIR i- CHECK AND REFILL WINDOW

CONDITIONER WASHING FLUID
A The cooler refrigerant is color- If there is mud or dust on the air Check the washing fluid levels in
washer tanks (1) and (2). When the
less and odorless and does not conditioner condenser, clean it with
cause pollution of the atmo- water. fluid has run short, add automotive
sphere. However it may cause * If the water pressure is too high, window washing fluid.
injury if it gets in the eyes or on the fins may get deformed. (I): Front window washing fluid tank
the hands, so never loosen any When washing with a high (2): Rear window washing fluid tank
parts of the refrigerant circuit. pressure washing machine, apply * To prevent the nozzles from
the water from a reasonable clogging, be careful not to let dust
distance. get into the fluid.
A with
Do not
a
wash the condenser
steam cleaner.
Otherwise, the condenser will
get hot and may break down.
w-04325
- 115 -
WHEN REQUIRED
k. CLEAN AXLE CASE BREATHER I. CHECKING OF GLOW PLUG OF

Carry out this procedure if there APS
is any mud or dirt stuck around the (Automatic priming system)
breather. Checking is performed in autumn
(when the ambient temperature is
Front Rear below 15’C).
,,,., ,,, 1. Remove the two glow plugs from
the engine intake manifold, and
clean them.
2. Check for any disconnection in
the wiring.
3. Replace the gasket with a new
part, then install the glow plug.
Remove all mud and dirt from Clean the breathers of the front
around the breather with brush. and rear axles in the same way.
Then, remove breather, immerse Do not let dirt get into the port
in cleaning fluid and clean. while breather is removed.
If dust sticks to area around
breather, clean with a brush.
- 116- W-04326
WHEN REQUIRED
m.REPLACE APS FUEL FILTER n. DRAIN WATER FROM

Before using APS in cold weath- * Clean the filter base, and check WATER SEPARATOR
er, replace the cartridge (once a that the filter gasket is not stuck r-l-7-
+ TO fuel filter
year). to the filter base.
1. Close the valve (1) at the front of If the old gasket is stuck to the
the APS fuel filter cartridge. filter base, oil will leak between
the new gasket and old gasket.
M
3. Fill the new filter cartridge with T
fuel, coat the packing surface From fuel tank
with engine oil, and install.
+ When installing, be careful not to
overtighten. When the cartridge 3
comes in contact with the pack- When float (2) is at or above red
ing face, tighten l/2 to 314 of a line (I 1, drain the water according to
turn by hand. the following procedure:
1. Loosen drain plug (3) and drain
the accumulated water until the
2. Using a filter wrench, turn the float reaches the bottom.
filter cartridge (2) to the left to 2. Tighten drain plug (3).
remove. 3. If the air is sucked into fuel line
when drain the water, be sure to
bleed air in the same manner as
for the fuel filter.
(See Fuel Filter Cartridge in
section.)
W-04327 - 117 -
ADJUSTMENT
ADJUSTMENT
PARKING BRAKE
If the parking brake fails to work
properly, adjust it in the following
manner.
4. Restore bolt retainer (I) to the A When adjusting the parking

original position and confirm that brake, be sure to put chocks on
the retainer is in locking position the tires so that the slippage
to bolt (2). can be prevented.
Confirm that the indication of the 5. There are two calipers in the
air pressure gauge is in the green parking brake, so adjust the other A Maintain the air pressure at a
range and then release the park- caliper in the same way. sufficiently high pressure to
ing brake. prevent the parking brake from
Turn bolt (2) clockwise while operating automatically while
pressing bolt retainer (1) and let adjusting the brake.
pads (3) on both sides come into To prevent a third person from
close contact with disc (4). operating the parking brake by
Back off bolt (2) a half turn mistake, be sure to attach a
counter-clockwise while pressing caution tag to the parking
bolt retainer (1). brake switch.
- 118- W-04328
ADJUSTMENT
FAN BELT AND TENSIONER

Method of replacement Adjustment procedure
Loosen lock nut (2). then loosen If noise comes from the belt,
bolt (3). tighten adjustment bolt (3) to make
3mm Push the tension pulley (I) in the A dimension 80 mm, and lock in po-
*
direction of arrow to a position sition with lock nut (2).
II
I + Tightening torque: 38 kgm
where the belt can be removed,
6
then replace the belt. Ir When the belt is new, A dimen-
* When changing belts, do not sion is about 100 mm.
only change one belt. Always
change as a set.
Check the lining for wear and re-

place the pad, if the thickness of the
lining is reduced to less than 3 mm.
* Ask your Komatsu distributor for
replacement of the pad.
A Take care not to stain the

brake pad and the disc surface
with oil or grease.
w-04329
- 119 -
TROUBLE SHOOTING GUIDE

This guide is not intended to cover every conditions, however many of the
more common possibilities are listed.
ELECTRICAL SYSTEM
Lamp does not glow brightly even when engine runs at high The starting motor disengages before the engine starts up.
speed. l Check and repair the wiring.
Lamp flickers while engine runs. l Charge the battery.
l Check for loose terminals and open-circuit wiring.
l Replace fan belt. The engine pre-heating monitor does not flash.
l Check and repair wiring.
Charge monitor does not go out even when engine runs at high l Replace the heater relay.
speed. l Replace the monitor.
. Replace the alternator.
l Inspect and repair wiring. The engine oil pressure monitor does not light up when engine
is stationary (when the starting switch is in ON position.)
Unusual noise is emitted from the alternator. l Replace the monitor.
l Replace the alternator. l Repair or replace the sensor.
. Check wiring.
Starting motor does not turn when starting switch is turned on
l Inspect and repair the wiring. Charge monitor does not light up when the engine is stationary.
l Charge the battery. (When the starting switch is in ON position.)
l Replace the monitor.
The pinion of the starting motor keeps going in and out. l Inspect and repair the wiring.
l Charge the battery.
Outside the glow plug is not warm when touched with the hand.
Starting motor turns the engine sluggishly. l Check and repair wiring.
l Charge the battery. l Replace the glow plug.
l Replace the starting motor. l Check and repair the pre-heater switch.
- 120- W-02107
ENGINE
The engine oil pressure monitor flashes. The engine does not start when the starting motor is turned
l Add the oil to the specified level. over.
l Replace the oil element. Add fuel.
l Check oil leakage from the pipe or the joint. Repair where air is leaking into fuel system.
l Replace the monitor. Replace the injection pump or the nozzle.
Check the valve clearance.
Steam is emitted from the front part of the radiator (the pres- l Check engine compression pressure.
sure valve). 0 Refer to the section of electrical system.
Engine oil temperature monitor flashes.
Supply the coolig water and check leakage. Exhaust gas is white or blue.
Replace fan belt. . Adjust to specified oil quantity.
Wash out inside of cooling system. l Replace with specified fuel.
Clean or repair the radiator fin.
Replace the thermostat. Exhaust gas occasionaly turns black.
Tighten the radiator cap firmly or replace the gasket of it. l Clean or replace the air cleaner element.
Replace the monitor. l Replace the nozzle.
l Check engine compression pressure.
l Clean or replace the turbocharger.
Combustion noise occasionally changes to breathing sound.

l Replace the nozzle.
Unusual combustion noise or mechanical noise.

. Replace with specified fuel.
l Check over-heating.
l Replace the muffler.
l Adjust valve clearance.
W-02108 -lZl-
CHASSIS
Transmission Disc brake

Engine is running but machine will not move. Brake does not work when pedal is depressed.
l Release parking brake. . Raise air pressure to specified level.
l Put directional lever in position properly. l Replace disc.
l Add oil to transmission case to the specified level. l Add brake oil.
. Bleed air from brake system.
Even at full throttle, machine moves slowly and lacks power.
l Add oil to transmission case to the specified level. Brake drags or stays applied
l Disassemble transmission strainer and clean. . Clean exhaust hole of treadle valve.
l Clean breather of power cluster.
Oil overheats l Check and repair slack adjuster.
l Add oil to transmission case to the specified level or drain oil.
l Use a suitable gear speed. Brake slips.
l Reduce time using torque converter at stall speed. l Replace disc.
. Check engine.
Parking brake
Abnormal noise is produced. Brake does not work properly.
l Add oil to transmission case to the specified level. l Adjust linkage.
l Clean brake pad.
Axle l Replace spring in air cylinder
Abnormal noise is produced. l Adjust or replace brake pad.
l Add oil to axle case to the specified level.
Steering
Steering wheel is heavy.
l Adjust steering gear.
l Check linkage, replace parts.
- 122- w-01371
Hydraulic system
Bucket lacks lifting power.
Bucket lifting speed is slow.
l Addoil.
0 Replace filter in hydraulic tank.
Many bubbles from in oil.

l Replace with specified oil.
l Addoil.
l Bleed air from oil line.
Oil pressure is too low.

l Add oil and bleed air
Cylinder vibrates when operating.

l Add oil.
w-01372 - 123 -
SERVICE METER
SERVICE METER
This meter indicates the in-
tegrated work hours. So, use it ac-
cording to the following
instructions.
0 Record the readings at the start l While engine is running, green

and the end of work, this is the pilot lamp on the service meter
work record of the machine. flashes to show the service
0 This record will indicate, when meter advances.
periodical maintenance is due.
l It also indicates the integrated
working hours when machine
problems are encountered.
* How the meter progresses
The service meter progresses by
1 when the engine is operated
for one hour, regardless of the
engine speed.
Consequently, if the engine is
running, the service meter will ad-
vance even if the machine does
not move.
- 124- X-01375
MACHINE AND ENGINE SERIAL NUMBERS
MACHINE AND ENGINE SERIAL NUMBERS
When calling for a service of

mechanic or when making
replacement-parts order, be sure to
give Komatsu distributor the ma-
chine and engine serial numbers as
well as the service meter reading
before mentioned. These numbers
are founds on the plates shown in
the photos below.
l Location of the machine serial l Location of the engine serial

number mark number mark
This is seen on the center right of This is seen on the right of the
the front frame. cylinder block, when seen from
the fan side.
- 125 -
FUEL, COOLANT AND LUBRICANTS

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
AMBIENT TEMPERATURE CAPACITY ( II )

KIND OF
RESERVOIR
FLUID -22 -4 14 32 50 68 86 104 122’F
-30 -20 -10 0 10 20 30 40 50°C Specified Refill
Engine oil pan 82 64
Brake Engine oil 10.3
Transmission case
Hydraulic system
Axle
See NOTE (4) each 360 each 360
(Front and rear)
Fuel tank
Cooling system Water Add antifreeze
- 126- w-02110
NOTE:
(I) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric tem-
change oil in the oil pan every periodic mainte- perature of lower than O”C, be sure to use engine
nance hours described in this manual. oil of SAEIOW, SAEIOW-30 and SAEl5W-40,
Change oil according to the following table if fuel even though an atmospheric temperature goes up
sulphur content is above 0.5%. to 10°C more or less in the day time.
Use API classification CD as engine oil and if API
classification CC, reduce the engine oil change in-
terval to half.
For axle oil, use only recommended oil as follows.
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBILAND SUPER UNIVERSAL
* It is possible to substitute engine oil CLASS-CD
SAE30 for axle oil.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
W-02175 - 127-
SAFETY AND OPERATION
CONTENTS
SAFETY HINTS . . . a . ....... ....... 2

PRECAUTIONS FOR MAINTENANCE . . ....... ....... 8
BUCKET OPERATION.. . .. . .. ....... ....... 12
OPERATING THE AIR CONDITIONER . . . . ....... ....... . 18
OPERATING THE CAR HEATER . ....... .. .. 21
LOCKING CAP . .. .. . .. .. ....... I . . . . . 23
RADIO . . ....... . . . .. . . .... . 24
HANDLING OF BATTERY.. .. .... . ... . 26
STORAGE . . . . .. . .. ... 29
COOLANT AND LUBRICANTS . . . .. . . 31
w-04330 -l-
SAFETY HINTS* . l A
Protect yourself and others. Safety is always first.
OPERATION
GENERAL
l Wear well-fitting helmet, safety l Confirm that all gauges and l Fuel or oil are dangerous
shoes and working clothes. If the warning devices are functioning substances.
nature of the work requires correctly, and that the gauge Never handle fuel, oil, grease or
safety, wear protective goggles readings are within the prescribed oily cloth in places where there is
or mask, thick gloves, ear plugs range. any fire of flame.
or other protection. l Learn about the safety devices
l Take care of your health. Do not on your own machine and about
operate when tired, or after how to use them.
drinking. l Never allow another person to
l When there is a leader, fix stan- operate the machine.
dard signals and always follow l If there should be an accident or
these signals when operating. fire or any other such unexpected
l Learn the prohibitions, cautions mishap, deal with it quickly,
and rules about work procedures using the nearest apparatus.
in the work site. Learn beforehand the locations
l Read the Operation and Mainte- of the first aid boxes and fire ext-
nance Manual carefully. Learn inguishers and how to use them.
how to use the control devices, It is also important to know the
gauges and warning devices. Be emergency contact system.
sure you understand the meaning
of the caution plates.
-2- ww-01241
BEFORE STARTING
CHECKING JOBSITE OPERATION
CONDITIONS CHECK BEFORE STARTING
l Examine the lay of the land and l Check the load limits of bridges l Carry out checks before starting
the kind of soil at the work site to before crossing. the machine. If any problem is
determine the dangerous points l When operating a machine in found, do not start the engine,
and the best method of water or fording streams, survey but inform the foreman
operation. the water depth, ground condi- immediately. Always keep the
Proceed with the work only after tion and velocity of the water in machine in good condition.
making safety arrangements advance. Do not take the machine l Before operating the machine, be
about the dangerous points. in water exceeding the allowable sure to check the bar and pins for
l Do not work when visibility is re- depth (up to the underside of the setting in storage position.
duced by smoke, fog or dust. If axle housing). The machine can not be steered
the jobsite is dark, install lighting l The overall height of the machine with frames locked. (In articulate
if necessary. is restricted by tunnels, roof frame model)
l Keep work site flat! height or overhead electric wires, l Always stop the engine when
By continually grading the work SO check first whether the jobsite adding fuel. After adding fuel,
site, work efficiency will be im- is safe. Be particularly careful tighten the fuel cap properly.
proved and machines will be able when working near power lines l Inspect the inside of the engine
to drive smoothly over the site. If as electric shock can be caused if room and remove any dead
the work site is very sandy or the machine touches the electric leaves or papers. Dead leaves or
dusty, sprinkle water over the cables. papers are highly inflammable
ground before working on the and can cause fires.
site.
W-01242 -3-
PRECAUTIONS WHEN GETTING PRECAUTIONS WHEN
ON THE MACHINE STARTING THE ENGINE
l Do not leave parts or tools lying l If the machine is fitted with a l Before starting the engine, con-
around in the vicinity of or on the cab, make sure the windows are firm that all control levers are in
. ..
floor of the operator’s compart- clean and check the vrsrbrlrty. neutral position.
ment. Keep everything in its Always lock the door before l Exhaust gas is dangerous. When
proper place. starting operations. working inside, be particularly
Wipe off thoroughly any grease, l When getting on or off the careful to have good ventilation.
oil or mud on the handrail, floor machine, use the handrail and l To ensure the safety of workers
or control levers. Failure to do step provided. Do not jump up near the machine, always sound
this may cause you to slip. onto or down from the machine. the horn to warn them before
l If a seat belt is provided, always starting the engine and moving
use it. If the belt is damaged or the machine. Be particularly care-
worn, replace it with a new one. ful to check that the rear is clear
before backing the machine.
-4- w-01243
DURING OPERATION
CHECKS AFTER STARTING THE
ENGINE ATTENTION TO SURROUNDINGS
l Before starting work, test drive l Always sit in the operator’s seat l To ensure the safety of workers
the machine in a safe place and when operating the machine. near the machine, always sound
check that the transmission, l Do not allow anyone except the the horn to warn them before
brakes, accelerator, and steering operator on the machine. starting the engine and moving
are working properly. At the l Always be aware of the operating the machine. Be particularly care-
same time, check that there is capacity of the machine. Using ful to check that the rear is clear
not abnormal noise or vibration, the machine to do work beyond before backing the machine.
or any abnormality in the instru- its capacity will not only damage l Do not allow unauthorized per-
ments and gauges. the machine, but may even cause sons into the work area.
unexpected accidents. l Always concentrate. It is ex-
l The machine condition can be tremely dangerous to allow your-
judged from many factors. self to be distracted or to think of
Changes in the gauges, sound, other things when operating a
vibration, exhaust gas color or re- machine.
sponse of the control levers can l When loading trucks or hoppers,
indicate the occurrence of some be careful not to hit the truck or.
disorder. If any disorder occurs, hopper with the bucket. Do not
park the machine immediately in bring the bucket over people’s
a safe place and take appropriate heads or over the cab of the
action. truck.
W-01244 -5-
RESTRICTIONS CREATED BY
JOBSITE
l In dangerous places or in places l Do not use the bucket as a brake l Do not approach the edge of the
..
where the vrsrbrlrty is poor, get except in emergencies. cliff or road shoulder.
down from the machine and l If the engine stops when the ma- l In dangerous places, always
check that it is safe before con- chine is traveling, it is impossible work in teams of two; one man
tinuing the operation. to use the steering. This is to operate the machine, and the
l Always operate slowly in crowd- dangerous, so apply the brake im- other to give instructions.
ed places. On haul roads or in mediately to stop the machine. l On windy days, always load
narrow places, give way to l When traveling on hills with a downwind.
loaded machines. loaded bucket, travel forward up l When continuing operations
l When traveling, keep the work the hill and in reverse down the after rain, remember that condi-
equipment close to the ground to hill. tions will have changed from
maintain the stability of the ma- l The machine should always be those before the rain started, so
chine. Pay particularly careful at- operated at a speed where it can proceed with caution.
tention to the stability of the ma- be correctly controlled. Never do Be careful when working on the
chine when traveling with a load. the following: place made of piled soil, after
l If the machine has to travel on * Speeding earthquakes or after blasting.
rough ground, be careful to avoid * Sudden starting, sudden brak- l Always travel directly up or down
obstacles as far as possible. ing, sudden turning slopes. When traveling down a
l Always travel at a slow speed, * Snaking slope, use the same gear speed
and do not suddenly change * Coasting as when going up the slope.
direction. When traveling down a slope,
never put the transmission in
neutral.
-6- w-03207
PARKING
l If the engine stops on a slope, l Before starting towing opera- l When parking the machine, park
apply the brake quickly and care- tions, make sure that no one is it in a safe place outside the
fully. Next, lower the work equip- near the machine. Start the ma- working area, or in the specified
ment to the ground and apply the chine slowly to take up the slack place. The following factors
parking brake. Then put the direc- in the wire rope. Then start should be considered when
tional and speed control levers in towing carefully. Do not tow any choosing a parking place: it
neutral, and start the engine machine whose brakes or steer- should be on flat, firm ground
again. ing have broken down. where there is no danger of rock-
l Be careful when traveling on falls, landslides or floods.
planks or steel plates, as these l If the machine has to be parked
can cause slippage. on a slope, it should be parked
l When operating at night, remem- facing directly up or down the
ber the following points: slope, and chocks should be
o Be sure to arrange an adequate placed under the tires.
lighting system. l When leaving the machine,
o At night it is very easy to make always lower the work equipment
mistakes in assuming the dis- completely to the ground, and
tance and height of objects put all control levers in neutral.
and land. Next, apply the parking brake and
l Before towing operations, lock all levers. Then put blocks
always check the wire rope. under the tires.
l After stopping the engine,
always remove the starting key.
-7-
W-03208
PRECAUTIONS FOR MAINTENANCE
GENERAL BEFORE MAINTENANCE

Wear well-fitting helmet, safety Always keep the work shop in Before starting work, stop the
shoes and working clothes. good condition. Make sure there machine on a firm, level surface,
When drilling, grinding or is no mud or oil on the floor. and use blocks to keep the ma-
hammering, always wear protec- Keep oily cloths and other com- chine from moving during
tive goggles. bustible things in a safe place operations.
When working with others, away from fire. In addition, learn Lower the bucket to the ground.
choose a group leader and work the location and method of oper- If this is impossible, use the
according to his instructions. Do ation of fire extinguishers. safety pin and blocks to hold the
not perform any maintenance Always stop the engine before work equipment securely in
beyond the agreed work. cleaning the machine or adding position. In addition, apply the
Hand a caution sign in the opera- fuel. locks to all control levers.
tor’s compartment (for example Flame should never be used in- Always lock the front and rear
“Do not start” or “Maintenance stead of lamps. Never use a frames before inspecting and ser-
in progress”). naked flame to check leaks or the vicing the machine.
This will prevent anyone from level of oil, fuel, anti-freeze or (In articulate frame model)
starting or moving the machine electrolyte. Remove all oil and mud from the
by mistake. l Always use non-inflammable machine. In particular, be sure
Smoke only in designated places. cleaning agents when cleaning that the steps, hand grips, and
Never smoke while working. parts. the floor of the operator’s com-
partment are clean.
Always use the standard ROPS
equipment. Do not modify the
ROPS equipment.
-8- w-01317
DURING MAINTENANCE MISCELLANEOUS

l When getting on or off the l Be particularly careful when l Thoroughly wash the machine,
machine, use the steps, hand removing the radiator cap or the particularly the oiling and greas-
grips and ladders. Never jump on hydraulic oil tank filler cap. If this ing parts and the vicinity, thereof,
or off the machine. If the steps, is done immediately after using in order to prevent the ingress of
hand grips, or ladder cannot be the machine, there is a danger dust.
used, use a stand to give firm that boiling water or oil may l Use genuine Komatsu replace-
footing. spurt out. ment parts specified in the parts
l If necessary, remove the cables l Always release the pressure in list.
from the battery terminals. When the circuit before checking or ser- l Use Komatsu specified oil and
charging the battery, make sure vicing the oil, water or air circuits. grease. Use oil and grease having
the area is well ventilated. l When the engine stops, the the recommended viscosity for
a Exhaust gas is dangerous. When water and oil in the circuit is hot, the particular ambient
working inside, be particularly so be careful not to get burned. temperature.
careful to have good ventilation. Wait for the water and oil to cool l Use clean oil and grease and
a When opening inspection covers, before starting any work on the keep them in clean containers’to
stop the engine. If the hood or machine. avoid the ingress of dust.
other covers are fitted with a l Inspect or replace oil in a dust-
lock, always apply the locks free location to prevent the in-
securely when opening or closing gress of dirt.
the hood or cover. l Drain off used oil after heating it
l Always stop the engine before to a suitable temperature (about
adjusting belt tension or before 20 to 40°C).
checking or servicing the water
pump.
W-01318 -9-
When the strainer is located in When washing the machine, When working on the sea shore,
the oil filler, the strainer must not ensure that water does not get carefully clean all electrical equip-
be removed while adding oil. onto the alternator. ment to ensure that is does not
When adding oil or checking the Special measuring apparatus is corrode.
oil level, check that the oil is at needed for testing hydraulic Before working in muddy water,
the correct level. pressure. rain or snow, check that the vari-
After greasing up, always wipe Thoroughly wash the machine. In ous plugs, valves, are properly
off the old grease that was particular, be careful to clean the screwed up. Upon completion of
forced out. filler caps, grease fittings and the work, wash the machine, then
When changing the oil or filter, area around the dipsticks. Be check the various parts of the
check the drained oil and filter careful not to let any dirt or dust machine for cracking, scratching,
for any signs of excessive metal into the system. loose or missing nuts and bolts.
particles or other foreign When check an open cover there Also, oil and grease the various
materials. is a risk of dropping things in. parts of the machine.
When removing parts containing Before removing the covers to in- When working on rocky ground,
O-rings, gaskets or seals, clean spect cover, empty everything be careful of damage to the
the mounting surface and replace from your pockets. Be particularly undercarriage, loose nuts and
with new sealing parts. careful to remove wrenches and bolts, cracks, wear and other
nuts. damage.
-lO- w-02145
l When working in a dusty loca- l After disconnecting the con-

tion, be careful of the following: nector, cover it with a vinyl bag
I) Inspect the dust indicator to see to prevent oil or dust from stick-
whether the air cleaner is ing to its contact section.
blocked up. Clean the air cleaner l When welding, be careful of the
as soon as it becomes dirty. following:
2) Clean the radiator core so that it 1) Turn OFF the power (starting
does not become blocked up. switch).
3) Clean or replace the fuel filter as 2) Do not continuously apply more
soon as it becomes dirty. than 200 V.
4) Clean the electrical equipment, 3) Install the ground cable at least
particularly the starting motor 1 m from the range to be welded.
and alternator, to prevent ac- 4) Take care not to install the seals
cumulation of dust. between the grounded point and
l When installing car radio and a the range to be welded.
walkie-talkie or citizen band, con- * Use ordinary automobile washer
tact your Komatsu distributor. fluid. Be careful not to let dirt or
l When washing the machine, take dust get in.
care not to splash water over the
electrical equipment. If it is
soaked with water, it may not
operate normally.
W-02707 -ll-
BUCKET OPERATION
BUCKET OPERATION
Various types of attachments are

available to extend the range of
application beyond the applica- When driving the machine for- 2. Shift down immediately in front
tions described below. ward and lowering the bucket, of the material to be loaded.
stop the bucket about 30 cm When completing the shift
EXCAVATION from the ground, then lower it down, depress the accelerator
slowly. pedal at the same time and thrust
When loading piled soil or blasted If the bucket hits the ground, the the bucket into the load.
rock, drive the machine forward front tires will come off the
as follows to load. To prevent ground, and the tires will slip.
cutting of the tires caused by the
tires slipping, be careful of the
following points during the
operation.
Always keep the operating jobsite
flat, and remove any fallen rocks.
When working with stockpiles,
operate the machine in 1 st or
stockpile
2nd, operate the machine in, 1 st
when loading blasted rock.
- 12 - W-03818
BUCKET OPERATION
3. When the material is in a stock- 4. At the same time as thrusting the 5. Check that there is enough mate-
pile, keep the cutting edge of the bucket into the material, raise the rial loaded into the bucket, then
bucket horizontal; when loading lift arm to prevent the bucket operate the bucket control lever
blasted rock, have the bucket tilt- form going in too far. By raising to tilt the bucket and load the
ing slightly down. the lift arm, ample traction will be bucket fully.
* Be careful not to get blasted rock produced by the front tires. * If the bucket edge is moved up
under the bucket. This will make and down while pushing in the
the front tires come off the bucket and digging, the front
ground and slip. tires will come off the ground
* Try to keep the load in the center and this will cause the tires to slip.
of the bucket; if the load is on
one side of the bucket, the load
will be unbalanced.
Blasted rock
W-03819 - 13-
BUCKET OPERATION
6. If there is too much material l When digging and loading on 2. Drive the machine forward and
loaded in the bucket, dump and level ground, set the bucket edge operate the lift arm control lever
tilt the bucket quickly to remove facing down slightly as follows forward to cut a thin layer of the
the excessive load. and drive the machine forward. surface each time when excavat-
This prevents spillage of the load Always be careful not to load the ing the soil.
during hauling. bucket on one side and cause an
unbalanced load.
* This operation should be carried
out in 1 St gear.
1. Set the edge of the bucket facing
slightly down.
3. Operate the lift arm control lever

slightly up and down to reduce
the resistance when driving the
machine forward.
W-03820
BUCKET OPERATION
LEVELING
1. Scoop soil into the bucket. Move
* When digging with the bucket,

the machine backward while
spreading soil from the bucket
A can
If leveling by forward
not be avoided,
travel
do not
avoid imposing the digging force little by little. dump the bucket beyond 20”.
onto only one side of the bucket. 2 Go over the spread soil with the This will prevent quick wear
bucket teeth touching the and damage of the work equip-
A machine
Never dig or scoop when
body is articulated.
the ground and level the ground by
back-dragging.
ment and frame.
3. Scoop some more soil into the

Precautions when scooping up bucket, put the lift arm in float,
materials. level the bucket at ground level,
When scooping up materials, be and smooth the ground by
careful not to let the counterweight moving backward.
at the rear touch the ground. * Always move the machine back-
* Do not allow tires slipping to ward during leveling operations.
occur during operation. Tires slip-
ping shortens tire’s life.
W-03821 -15-
BUCKET OPERATION
LOAD AND CARRY LOADING

OPERATIONS Select and proceed effective op-
Load and carry operation is a eration which avails less turning and
series of processes (scooping - the shortest hauling distance ac-
carrying - loading to a hopper or cording to ground conditions.
glory hole) carried out by the wheel
loader. CROSS DRIVE LOADING
* Always maintain the road in good When a wheel loader is operated,
condition. the digging should be made at a
right angle toward accumulated soil.
A Lower
down
the bucket
the center
to bring
of gravity
When the scooping is completed,
the machine should be traveled
when carrying material. backwards as it is. Then, bring the
truck between the accumulated soil
and the wheel loader for the purpose
of loading upon the dump truck.
A Provide a flat road free of rocks

and hollows. When the boom is
raised with the bucket loaded,
do not make quick turns or
quick braking because it is
very dangerous.
A Do not load the bucket

thrusting into a pile of soil or
by
gravel at high speed because it

is dangerous.
-16- W-03822
BUCKET OPERATION
V-SHAPE LOADING
Stop the truck with the angle of
about 60” toward the scooping di-
rection of the wheel loader. After
scooping the soil, back the wheel
loader in such a way that it makes a
right angle to the truck. The loading
on the truck is made by the wheel
loader going forward.
The smaller the turning angle, the
higher the efficiency. However, turn-
ing of 90” can be made if necessary.
W-03823 - 17 -
OPERATING THE AIR CONDITIONER

EQUIPMENT ON CONTROL
It is possible to use the air condi- PANEL
tioner to good effect in dusty job-
sites. The outside air is passed
3
l
Fan switch
This controls the air flow when
a
l
Air conditioner switch
This is the control switch for
through the filter and is sent to the the air conditioner is used for cooling.
operator’s cab to increase the pres- cooling or heating. ON:
sure inside the cab. In this way, dust o There are 3 levels: When this button is pressed,
is prevented from entering, so com- L (Low), M (Medium), the dehumidifying and cooling
fortable operating conditions are and H (High). systems are switched ON.
always maintained for the operator. The green lamp inside the
button lights up to indicate
that cooling is in operation.
OFF:
If the button is pressed when
the cooling is ON, the cooling
is switched OFF.
* Turn the fan switch on before

turning the air conditioner switch
on.
-18- W-03824
0 Air selector lever Precautions for using air Handling the air conditioner in
l This lever switches the source conditioner season
for the cooling air or heating air. When cooling, change the air To use the air conditioner com-
o FRE (fresh air) occasionally. fortably during its season, ask your
Fresh air is brought into the l Smoking in the air-conditioned Komatsu distributor to check the air
cooling system from outside. cab will cause your eyes to get conditioner and add the refrigerant
(This position is used for sore. While smoking, open the if necessary.
normal cooling and heating, window to let the smoke out of
and when increasing the pres- the cab. Handling the air conditioner in
sure inside the cab.) l While using the air conditioner, off-seasons
o REC (recirculate) open the window once every To lubricate each part of the
The air conditioning system hour. compressor during the off-seasons,
uses only the air inside the cab. operate the air conditioner for a few
(This position is mainly used Be careful not to overcool the minutes two or three times a month.
for cooling or heating the air cab.
inside the cab quickly.) The cab should feel cool when
entering there from outside (5°C or
@Temperature control lever 6°C lower than the outside
l This lever regulates the tempera- temperature). It is not good for the
ture when cooling. health to have the temperature in
o The closer the lever is to the cab too low. Always give careful
COOL, the lower the tempera- consideration to temperature
ture of the air becomes. regulation.
o The closer the lever is to
WARM, the higher the tem-
perature of the air becomes.
W-01282 - 19-
METHOD OF OPERATION
SELECTING AIR VENT OPERATION OF CONTROL PANEL
COOL (moved fully to COOL side)
Dehumidify-
H-L ON Middle - WARM FRE
ing, heating
WARM
P Quick H OFF REC
‘,= (moved fully to WARM side)
m
FOOT DEF I” Normal H-L OFF Middle -WARM FRE
Middle - WARM (to remove frost

Defrosting H ON quickly or to prevent the window
FRE
from misting up, move the lever
to the top)
Ventila-
tion or pres- H-L OFF COOL (move fully to COOL side) FRE
surizing
The effectiveness of the air con-

ditioning system can be increased * If the outside air is extremely
by selecting the most suitable dusty, set the fan switch to the H
vent. position. This will pressurize the
Do not turn the fan switch on cab and prevent the dust from
when all the vents are closed. entering.
- 20 -
W-00058-A
OPERATING THE CAR HEATER

EQUIPMENT ON CONTROL
PANEL
It is possible to use the car heater @Fan switch 0 Air selector lever
to good effect in dusty jobsites. The l This controls the air flow when l This lever switches the source
outside air is passed through the the car heater is used for heating. for the heating air.
filter and is sent to the operator’s 0 There are 3 levels: 0 FRE (fresh air)
cab to increase the pressure inside L (Low). M (Medium) and Fresh air is brought into the
the cab. In this way, dust is prevent- H (High) heating system from outside.
ed from entering, so comfortable ,(This position is used for
operating conditions are always @ Temperature control lever normal heating, and when in-
maintained for the operator. l This lever regulates the tempera- creasing the pressure inside
ture when heating. the cab.)
o The closer the lever is to o REC (recirculate)
WARM, the higher the tem- The heating system uses only
perature of the air becomes. the air inside the cab. (This po-
sition is mainly used for heat-
ing the air inside the cab
quickly.)
W-03825 -21 -
METHOD OF OPERATION
SELECTING AIR VENT OPERATION OF CONTROL PANEL
Air selector
Temperature control lever
lever
Quick H WARM (moved fully to WARM side) REC

Heating -
Normal H-L Middle -WARM FRE
Middle d WARM (to remove frost quickly

Defrosting H or to prevent the window from misting FRE
up, move the lever to the top)
Ventilation or
H-L COOL (move fully to COOL side) FRE
Open or Open or pressurizing
Heating Open
closed closed
Defrosting Open or
Closed Open
closed
Ventilation Open Open Open
* The effectiveness of the heating * If the outside air is extremely

system can be increased by dusty, set the fan switch to the H
selecting the most suitable vent. position. This will pressurize the
* Do not turn the fan switch on cab and prevent the dust from
when all the vents are closed. entering.
- 22 - w-00061 -.4
LOCKING CAP
LOCKING CAP
A locking cap is available as an

optional radiator cap, fuel tank cap
or hydraulic tank cap. Open and
close locking caps as follows:
1. To open the cap 2. To lock the cap
1) Insert the key into the cap. 1) Turn the cap into place. + When the cap is locked (against
+ Insert the key as far as it 2) Turn the key clockwise and vandalism), it rotates freely.
will go. If the key is turned take the key out.
before it is inserted all the
way, it may break.
2) Turn the key counterclockwise
and bring the rotor groove in
line with the aligning mark on
the cap. Turn the cap slowly
until a “clicking” sound is
made. This releases the lock
and allows the cap to be
opened.
W-03826 - 23.-
RADIO
RADIO
TUNING KNOB -TONE CONTROL

How to set station selector
Tune this knob in to the desired station. Use this knobto adjust the tone as desired.
Tune right in to the station. If the tuning When it is turned to the right the high buttons
is off center, the sound quality will be un- tones will be emphasized, and when it turn- Set the station selector buttons
natural and sensitivity will be reduced. ed to the left the high tones will be cut, re-
to the desired stations as shown in
sulting in a mellow tone.
POINTER the following figure.
POWER SWITCH/
VOLUME CONTROL
/ Press this knob to turn on (or off)
STATION
ISELECTOR BUTTONS
the radio. When it is turned to the
right, the sound level will increase,
and vice-versa. I. Pull back the button correspond-
(5 buttons) ing to the station to be
By pressing these buttons it is
possible to tune in to preset stations.
preselected.
/
2. Turn the station selector knob

until the pointer is in front of the
desired station. (Carefully tune in
so that noise disappears and the
broadcast is heard plainly.)
- 24 - W-03827
RADIO
Precautions when using radio Trouble shooting guide

To prevent possible breakdown,
keep water well away from the No sound
speaker case and interior of the l Turn the SWIVOL knob to the
radio. In particular, close the right and press it two or three
window during rain or when times.
washing the machine.
Do not wipe the dial plate or Sound quality is poor.
knobs with benzine or paint thin- Reception is noisy.
ners, etc. Always use a dry, soft l Return using the station selector
cloth (if the radio is particularly knob. If the problem disappears,
3. Carefully push back the button dirty, soak the cloth in alcohol). reset the tuning button.
with the fingertip until it clicks Do not disassemble the radio. l Try lengthening the antenna to
into place. its fullest extent.
* When setting the turning selector

to a strong station, shorten the
antenna to reduce the input as
far as possible before carrying
out alignment.
P-02446 - 25 -
HANDLING OF BATTERY
HANDLING OF BATTERY
PRECAUTIONS FOR CHARGING
BATTERY
1. Before charging, disconnect the 3. If the electrolyte temperature ex- 6. Do not mix up cables (positive
cable from the negative (-1 ceeds 45”C, stop charging for a (+I to negative (-1 or negative
terminal of the battery. while. I-1 to positive (+_)I, as it will
Otherwise, an unusually high vol- 4. Turn off the charger as soon as damage the alternator.
tage will damage the alternator. the battery is charged. 7. When inspecting or servicing a
2. While charging the battery, Overcharging the battery may battery, be sure to stop the
remove all battery plugs for satis- cause followings: engine and turn the starting
factory ventilation. I) Overheating the battery switch key to “OFF” position.
To avoid gas explosions, do not 2) Decreasing the quantity of 8. When performing any service to
bring fire or sparks near the electrolyte. battery besides checking the
battery. 3) Damaging the electrode plate. electrolyte level or measuring the
5. If the electrolyte gets on your specific gravity, disconnect
skin or clothes, immediately cables from the battery.
wash with plenty of clean water.
- 26 - w-01307
HANDLING OF BATTERY
REMOVAL AND INSTALLATION STARTING ENGINE WITH A 2. Connect the booster cables in
OF BATTERY BOOSTER CABLE the following manner.
A ~.
When removing battery,
disconnect the cable with the
first
with
When
a
starting
booster
up the engine
cable, do as
I) Connect one clip of booster
cable A to the positive (+I
black tube from the ground follows: terminal of the engine to be
(normally, from the negative 1. Before connecting the booster started.
(-) terminal). If a tool touches cable 2) Connect the other clip to the
a cable connecting the positive 1) Size of booster cable and clip positive (+I terminal to the
terminal and the chassis, there should be suitable for the bat- engine which is running.
is danger of sparks being tery size. 3) Connect one clip of booster
emitted. 2) Check cables and clips for cable B to the negative (-1
When installing battery, the breaks, corroded surfaces, etc. terminal of the engine which is
ground cable should be connect- 3) Make sure cables and clips are running.
ed to the ground terminal as the firmly secured. 4) Connect the other clip to the
last step. 4) Keep the starting switch in engine block to be started.
There is a total of four batteries “OFF” position. * Make sure the clips are firmly
(two on each side) at the rear of 5) The battery of the running connected to battery terminals.
the machine, and a total of two engine must be the same Then, start the engine.
batteries at the ground end (one capacity as that of engine to
on each side of the machine). be started.
When removing or installing the
batteries, always follow the
above procedure for the batteries
Batterv for running
on both sides.
f for engine
to be started
c (4
Engine block to be started &==
w-04331 - 27 -
HANDLING OF BATTERY
* If the battery capacity of the After the engine has started,

normal machine is smaller than the booster cables should be dis-
the battery capacity of the failed connected in the reverse order in
machine, use two normal which they were connected.
machines. Connect the booster 1. Disconnecting the booster cables 3) Disconnect the clip of booster
cable from one machine to the I) Disconnect the clip of booster cable A from the positive (+I
battery on the right side of the cable B from the engine block terminal of the running engine.
failed machine; connect the which was started. 4) Disconnect the other clip from
booster cable from the other ma- 2) Disconnect the other clip from the positive (+I terminal of
chine to the battery on the left the negative (-1 terminal of the engine which was started.
side of the failed machine using the running engine.
the same procedure.
A When connecting the cables,
never contact the positive (+I
and negative (-1 terminals.
A Make sure that the booster
cable connections are correct.
Connect the booster cable to
the engine block as far as possi-
ble from the battery.
3. Starting engine
1) Turn the starting switch to
START position and start up
the engine. Batterv for enaine which was started
2) If the engine doesn’t start at (l&&J @ (2) -
first, try again after 2 minutes Engine block which was started
or so.
- 28 - ww -02053
STORAGE
STORAGE
BEFORE STORAGE
To place the machine in storage l Apply a thin coat of grease to When the ambient temperature
for an extended period of time, the metal surface (hydraulic piston is anticipated to drop below O”C,
following measures must be taken rods and splined shaft). always add antifreeze in the cool-
to insure that it can be returned to l As to batteries, remove the termi- ing water.
operation with minimum of service. nals and cover them, or remove Set each control levers to neutral
After every part is washed and them from the machine and store or hold position, lock them and
dried, the machine shall be separately. apply the parking brake.
housed in a dry building. Never Open the drain valve of the air
leave it outdoors. tank to drain condensation. Close
In case it is indispensable to leave after completely drained.
it outdoors, lay wood plates on
the ground, and park the machine
on the wood plates and cover it
with canvas etc.
Completely fill fuel tank, lubricate
and change oil before storage.
w-01373 - 29 -
STORAGE
DURING STORAGE AFTER STORAGE

l Operate the engine and move the After storage (when it is kept l You should request Komatsu dis-
machine for a short distance without cover or the rust-preventive tributor for following service.
once a month so that new oil film operation once a month is not o Remove the cylinder head
will be coated over movable made), you shall apply the following cover and lubricate sufficiently
parts and component surfaces. treatment before operation. valves and rocker arms. And
l Before operating the work l Wipe off the grease on the hy- inspect the valve operation.
equipment, wipe off the grease draulic piston rod. o Remove the oil pipe flange on
on the hydraulic piston rod. l Loosen the drain plugs on oil pan the turbocharger oil inlet, fill
and other cases and drain mixed with 0.5 to 1 I! engine oil, and
A If it is unavoidably necessary water. leave the flange lightly
to carry out rust-preventive op- loosened. Then, rotate the
eration while the machine is engine by the starting motor
indoors, open up doors and win- without fuel injection and
dows to improve vetilation and decompression so that the dis-
prevent the gas poisoning. charge of oil is confirmed.
Then, tighten the flange and
start the engine.
l After the engine is started, oper-
ate it until it is warmed up
completely.
- 30 - ww-01374
COOLANT AND LUBRICANTS

Engine Oil Grease Anti-Freeze Coolant
[CD] Gear Oil
No. [GL-4, GL-51 [Lithium-Basal [Ethylene Glycol Base1
Supplier Name SAElOW, SAE30,
SAElOWl30. SAE15Wl40 SAESO, SAEl40, NLGI-2 [Permanent Type]
Diesel Sigma S
1 AGIP ROTRA MP GR M _
Superdiesel Multigrade
2 AMOCO Amoco 300 Multi-Purpose Gear Super Permalube Grease -
3 ARC0 Arco Fleet S-3 Plus HD Gear Oil Litholine H-EP -
Hypoidgear EP Energrease ~2
4 BP Vanellus C-3 Antifreeze
Gear Oil EP Enerqrease LS2
RPM Delo 300 Multipurpose Thuban EP Marfak Multipurpose

5 CALTEX AF Engine Coolant
RPM Delo 400 Universal Thuban Marfak All Purpose
RX Super Hvpoy, Hipress

6 CASTROL LM Grease Ant if reeze
CRD HVP~Y B, HYPOV C
Delo 300 Multi-Motive Grease

7 CHEVRON Universal Gear _
Delo 400 Ultra-Duty Grease 2 I
Multiperformance 3C Tranself EP Multi

8 ELF Glacelf
Performance 3C Tranself EP Type B EPEXA 2
Essolube D-3 Multi Purpose Grease

Gear Oil GP
9 EXXON (ESSO) Essolube XD-3 Beacon 2 -
Gear Oil GX
Essolube XD-3 Extra Beacon EP2
W-04332 -31-
Engine Oil Grease Anti-Freeze Coolant

Gear Oil
[CD1 [Lithium-Base] [Ethylene Glycol Base1
No. Supplier Name tGL-4, GL-51
SAElOW, SAE30, NLGI-2 [Permanent Type]
SAESO, SAE140,
SAE10W130, SAE15Wl40
Multi-Purpose Gear Gulfcrown Grease No. 2 Cruisemaster Antifreeze

10 GULF Super Duty Hypoid Gear All Purpose Gulfcrown EP Special and
Tvpe Grease No. 2 Summer Coolant
Delvac 1300 Mobilgrease MP

Mobilube HD Mobilgrease 77
11 MOBIL Delvac 1400 Permazone
Mobilube GX Mobilgrease 532
Delvac 1400 Super Mobilux EP2
No.4092
Supreme Duty Fleet Multi-Purpose No. 705 Anti Freeze &
12 PENNZOIL Multi-Purpose Gear No.4096
Multi-Duty Wheel Bearing No.707L Summer Coolant
No.4140
Rimula Spirax EP -
13 SHELL Alvania Grease EP
Rimula X Spirax Heavy Duty
Sunfleet Dieselube XL Sunfleet HP Sunoco Multi-Season

14 SUN Sunfleet GL-5
Sunfleet Super C Sun Prestige 7.42 EP Anti-Freeze
Ursa Super Plus

Multigear Lubricant EP Marfak All Purpose Startex AF &
15 TEXACO Ursa Oil LA
Thuban Marfak Multi Purpose 2 Summer Coolant
Ursa Super LA
Rubia S TOTAL EP
16 TOTAL Multis EP2 Antifreeze
Rubia x Transmission TM
17 UNION Guardol MP Gear Lube LS Unoba EP
- 32 - w-04333
Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVISION
Fax No. (847) 9704186
FOR INTERNAL USE ONLY -- No. PMR
’ NAME OF COMPANY: LOCATION:

1
AACHINE MODEL:
i/N IF APPLICABLE:
‘AGE NO:
‘ROBLEM:
Wach photo or sketch.

f more space is needed, use another sheet
FOR INTERNAL USE ONLY

:ORRECTIVE ACTION:
PFMRI 081696

Operation & Maintenance Manual: Wheel Loader

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Operation & Maintenance Manual: Wheel Loader

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Operation & Maintenance SEAM042801 02

BREAKING IN YOUR NEW MACHINE

For replacement procedure and

GENERAL LOCATIONS AND SPECIFICATIONS

INSTRUMENTS AND CONTROLS

Sr To check the monitor immediate- @CAUTION MONITOR @J METER GROUP

A: CHECK MONITOR GROUP

mality at the same time.

1131 ate monitor lamp and the warning

This monitor indicates clogging This monitor indicates a drop in

2. ENGINE OIL PRESSURE 3. COOLANT LEVEL MONITOR 4. AIR PRESSURE MONITOR

5. COOLANT TEMPERATURE 6. TORQUE CONVERTER OIL 7. EMERGENCY STEERING

When using APS (automatic

4. AFTERHEATING MONITOR 5. TRANSMISSION CUT-OFF 6. AIR PRESSURE GAUGE

7. ENGINE COOLING WATER 8. TORQUE CONVERTER OIL 9. FUEL GAUGE

This lamp lights up when the

2. FUEL CUT-OFF SWITCH 3. ENGINE LOW IDLING 4. HAZARD LAMP SWITCH

5. PARKING BRAKE SWITCH

6. WORKING LAMP SWITCH 7. PREHEATER SWITCH

When the front and rear working

8. STARTING SWITCH 9. HORN BUTTON

When the button in the center of

10. LAMP SWITCHES

Lamp switch Turn signal lever + When the steering wheel is

11. FRONT WIPER SWITCH 12. REAR WIPER SWITCH

@ The wiper is actuated at low When this switch is pulled to ON

13. CIGARETTE LIGHTER 14. ROOM LAMP SWITCH

This is used to light cigarettes. When this switch is moved to ON

PEDALS AND LEVERS

1. ACCELERATOR PEDAL 2. BRAKE PEDALS

A Do not use the brake pedals as

* When the accelerator is being

3. DIRECTIONAL LEVER 4. SPEED CONTROL LEVER

+ The engine cannot be started if

5. SPEED CONTROL LEVER 6. STEERING COLUMN TILT

7. LIFT ARM CONTROL LEVER

8. BUCKET CONTROL LEVER 9. SAFETY LOCK

DUST INDICATOR CIRCUIT BREAKER (MAIN) SAFETY BAR

Circuit breaker is in cover behind

reset all six breakers in the breaker 10A Hazard lamp

Circuit breaker II Circuit breaker IV

0 10A Turn signal lamp 0

0 10A Brake lamp, Back up lamp 0 I 10A Radio, Room lamp

0 IOA Transmission control valve 10A Cigarette lighter

Circuit breaker III Circuit breaker V

0 IOA APS (automatic priming system)

0 IOA Monitor panel @ ) tOA ( Rear working lamp

0 10A Rear working lamp 0 I IOA -

8 10A Front working lamp @ I IOA

OPERATOR’S SEAT RIGHT SIDE ARMREST

C: Seat cushion adjustment

3. Sit in the seat. Hold buckle (2)

REMOVAL AND INSTALLATION OF BUCKET

the frame, ground the bucket,

2. Check that there is nothing

* After inserting, rotate flange 1 to * When inserting pin, do not

3. Fill the space between oil seal (2)

Grease 6 Assemble mounting side of the

Sr Adjust the thickness of the

CHECK BEFORE STARTING

a. WALK-AROUND CHECK b. CHECK MONITOR PANEL c. CHECK AND REFILL COOLANT

d. CHECK OIL LEVEL AND REFILL

A Do not remove the cap while 1. Open the inspection ‘window at