WA900-3LC PALA Operacion y Mtto.

CEAM004002
Operation & Maintenance

Manual
WA900-3LC
WHEEL LOADER
SERIAL NUMBERS WA900-3LC - A50001 and UP
This material is proprietary to Komatsu Mining Systems and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu Mining Systems.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
September 2002 Copyright 2002 Komatsu

DataKom Publishing Division
EMISSION CONTROL WARRANTY
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)
1. Products Warranted
Komatsu America International Company, Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collectively “Komatsu”) produce and/or
market products under brand names of Komatsu, Dresser, Dressta, Haulpak and Galion. This emissions warranty applies to new engines bearing the
Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to
these engines produced on or after January 1, 2000. This warranty will be administered by Komatsu distribution in Canada.
2. Coverage
Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform, at the
time of sale by Komatsu, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in
workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as
measured from the date of delivery of the engine to the ultimate purchaser.
3. Limitations
Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. Komatsu is not responsible for
failures or damage resulting from what Komatsu determines to be abuse or neglect, including, but not limited to: operation without adequate coolant
or lubricants; over fueling; over speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in
or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water,
dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs, “downtime” expense, related damage, fines, all business
costs or other losses resulting from a warrantable failure.
KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER
WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT):
1. Produits garantis:
Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/ou font la
mise en marché de produits portant les noms de marque Komatsu, Dresser, Dressta, Haulpak et Galion. Cette garantie sur les émissions s’applique à tous les
nouveaux moteurs portant le nom Komatsu, installés dans ces produits et utilisés au Canada dans des machines conçues pour utilisation industrielle non-
routière. Cette garantie s’applique seulement sur les moteurs produits à partir du 1er Janvier 2000. Cette garantie sera administrée par la distribution de
Komatsu au Canada .
2. Couverture:
Komatsu garantit à l’acheteur ultime et chaque acheteur subséquent que le moteur est conçu, construit et équipé en toute conformité, au moment de la vente
par Komatsu, avec toutes les Réglementations fédérales américaines sur les émissions applicables au moment de la fabrication et qu’il est exempt de défauts
de construction ou de matériaux qui auraient pour effet de contrevenir à ces réglementations en dedans de 5 ans ou 3000 heures d’opération, mesuré à partir
de la date de livraison du moteur au client ultime.
3. Limitations:
Les bris, autres que ceux résultant de défauts de matériaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu n’est pas responsable pour
bris ou dommages résultant de ce que Komatsu détermine comme étant de l’abus ou négligence, incluant mais ne se limitant pas à: l’opération sans
lubrifiants ou agent refroidissants adéquats; la suralimentation d’essence; la survitesse; le manque d’entretien des systèmes de lubrification, de
refroidissement ou d’entrée; de pratiques non-propices d’entreposage, de mise en marche, de réchauffement, de conditionnement ou d’arrêt; les
modifications non-autorisées du moteur. De plus, Komatsu n’est pas responsable de bris causés par de l’essence inadéquate ou de l’eau, des saletés ou autres
contaminants dans l’essence. Komatsu n’est pas responsable des réparations non-reliées au moteur, des dépenses encourues suite aux temps d’arrêts, des
dommages relatifs, amendes, et de tout autre coût d’affaires ou autres pertes résultant d’un bris couvert par la garantie.
KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSÉQUENTS.
Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL N’Y A AUCUNE AUTRE
GARANTIE, EXPRESSE OU SOUS -ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIÈRE.
CEKQ000600 - Komatsu America International Company 12/99

INFORMATION IMPORTANTE SUR LE MOTEUR AVERTISSEMENT
CE MOTEUR EST CONFORME AUX NORMES AMÉRICAINES DEL’EPA (ANNÉE DU DES BLESSURES PEUVENT RÉSULTER ET LA GARANTIE
MODÈLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNI- S’ANNULER SI LES RPM DU TAUX D’ESSENCE OU L’ALTITUDE
TION PAR COMPRESSION. CE MOTEUR EST CERTIFIÉ POUR OPERATION À ESSENCE EXCÈDENT LES VALEURS MAXIMALES PUBLIÉES POUR CE
DIÉSEL. MODÈLE ET SON APPLICATION.
IMPORTANT ENGINE INFORMATION

THIS ENGINE CONFORMS TO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA
REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTI-
FIED TO OPERATE ON DIESEL FUEL.
MODÈLE DU MOTEUR WARNING NO. SÉRIE
INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL RATE RPM OR ALTITUDES EXCEED
PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION.
FAMILLE DU MOTEUR ENGINE MODEL SERIAL NO. DÉPLACEMENT
SYSTÈME DE ENGINE FAMILY DISPLACEMENT LITERS

CONTROLE DES
ÉMISSIONS D’ÉCHAPPEMENT EXHAUST EMISSION
FIRING ORDER 1-5-3-6-2-4 LITRES
CONTROL SYSTEM
ADV. LOAD OUTPUT Kw ( HP) RPM
CHARGE DE SORTIE ADV. SÉQUENCE DE MISE À FEU
VALVE LASH IN. EX. FUEL RATE mm3/STROKE mm3/BATTEMENT
PORTÉE DE VALVE À FROID COLD (mm) AT ADV.
(mm) TAUX D’ESSENCE À ADV.
VITESSE STATIQUE IDLE SPEED RPM FAMILY EMISSION LIMIT

INITIAL INJECTION DEG. BTDC DATE OF MANUFACTURE LIMITE D’ÉMISSION DE
TIMING LA FAMILLE
RÉGLAGE DE L’ALLUMAGE - _____________________________________________ KOMATSU LTD.

INJECTION INITIALE MADE IN JAPAN DATE
DE FABRICATION
DEG. BTDC
KOMATSU LTÉE
FABRIQUÉ AU JAPON
ENGINE DATAPLATE - ENGLISH / FRENCH

PRODUCT PUBLICATIONS INFORMATION
Various product Parts and Service Publications are available to all KOMATSU mining equipment
owners, including operation and maintenance manuals, parts books and service manuals.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB006100
OPERATION AND MAINTENANCE MANUAL:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM004002
SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM003701
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM002602
SAFETY MANUAL
Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT70-1
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the
Komatsu Mining systems Parts Inventory Processing System (PIPS) or the Extranet Literature Ordering
System.
If the PIPS system is not available at the distributor location, then the following Requisition for Technical
Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this
page.
WA900-3 pubinfok.fm 9/6/02

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO ö DataKom Publishing Division
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO ö
ATTN.
STREET ADDRESS ORDER DATE

TYPE or PRINT CITY, STATE, ZIP CODE
ONLY ö
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
PARTS BOOK
PUBLICATION
QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER
DESCRIPTION
M-Microfiche
KDC91E 072199 CURRENT PRICES WILL BE CHARGED

0INTRODUCTION
WA900-3LC 0-1
INTRODUCTION
FOREWORD
This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the
operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and
maintenance.
Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read,
request a replacement manual from your local distributor.
If you sell the machine, be sure to give this manual to the new owner.
Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this
manual. Consult your local distributor or KOMATSU MINING SYSTEMS for the latest available information on your
machine or for questions regarding information in this manual.
This manual may contain attachments and optional equipment that are not available in your area. Consult your local distributor
or KOMATSU MINING SYSTEMS for those items that you may require.
Improper operation and maintenance of this machine can be hazardous and could result in serious injury
or death.
• Operators and maintenance personnel must read this manual thoroughly before operating or
maintaining this machine.
• This manual should be kept near the machine for reference and periodically reviewed by all personnel
who operate it.
• Some actions involved in operation and maintenance can cause a serious accident, if they are not
performed in the manner described in this manual.
• The procedures and precautions given in this manual apply only to intended uses of the machine. If
you use your machine for any unintended uses that are not specifically prohibited, you must be sure
that it is safe for you and others. In no event should you or others engage in prohibited uses or actions
as described in this manual.
• KOMATSU MINING SYSTEMS delivers machines that comply with all applicable regulations and
standards of the country to which it has been shipped. If this machine has been purchased in another
country or purchased from someone in another country, it may lack certain safety features and
specifications that are necessary for use in your country. If there is any question about whether your
product complies with the applicable standards and regulations of your country, consult your local
distributor or KOMATSU MINING SYSTEMS before operating the machine.
The description of safety is given in SAFETY INFORMATION and in SAFETY section 1.★
0-2 WA900-3LC
INTRODUCTION
SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. To
avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before
performing maintenance and machine operations.
To identify safety messages in this manual and on machine product graphics, the following signal words are used:
DANGER! This word is used on safety messages and product graphics where there is a high probability of serious injury or
death if the hazard is not avoided. These safety messages and product graphics usually describe precautions that
must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the machine.
WARNING! This word is used on safety messages and product graphics where there is a potentially dangerous situation,
which could result in serious injury or death if the hazard is not avoided. These safety messages and product
graphics usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may
also result in serious damage to the machine.
CAUTION! This word is used on safety messages and product graphics for hazards, which could result in minor or
moderate injury if the hazard is not avoided. These safety messages and product graphics might also use this
word for hazards where the only result could be damage to the machine.
Remark
This word is used for precautions that must be taken to avoid actions, which could shorten the life of the
machine.
Safety precautions are described in SAFETY section 1. ★
KOMATSU MINING SYSTEMS cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety message in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and
others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of
some procedures, contact your local distributor or KOMATSU MINING SYSTEMS.
WA900-3LC 0-3
INTRODUCTION
INTRODUCTION
INTENDED USE
This WHEEL LOADER is designed to be used mainly for the following work:
• Digging operations • Pushing operations

• Leveling operations • Loading operations
For details on operating procedures, see “OPERATION” on page 2-1
FEATURES
1. Easy to operate work equipment
• By using the kick down switch installed to the knob on the boom control lever, it is possible to shift down from 2nd to
1st, thereby providing speedy digging and loading operations.
• The powerful digging force and drawbar pull make it easy to dig and scoop up loads.
• The large dumping clearance and reach make it easy to load dump trucks.
• The excellent acceleration and production per unit of fuel make this a very economical machine.
• Installation of bucket corner teeth and wear plates between the teeth give the bucket a large resistance to wear.
2. Easy to operate machine
• The electrical transmission control provides light gear shifting, enabling finger control.
• The length of both the directional and speed levers can be adjusted individually.
• The PPC valve (proportional pressure type) provides good response when raising the boom and little operating force
is required.
• A wrist rest is provided by the control levers to improve the ease of control.
3. Operating comfort
• The sealed pressurized cab with air conditioner make pleasant operations possible.
• A fabric seat is used for the operator’s seat to give the operator a good ride.
• A low vibration cab and viscous mount are employed.
4. High levels of safety
• Safety is ensured by the good visibility from the cab, the wide area around the operator’s seat, steps for getting on and
off the machine, and the walk through floor at the rear of the cab.
• The rear access step offers safety when the operator gets on and off the machine with something in his hands.
• With the handrail and nonskid treatment on the top of the hood, the operator can check the area safely.
• Checks before starting, and checks for abnormalities during operation can be carried out using the machine monitor.
• Maintenance free wet type multiple disc brakes are used.
0-4 WA900-3LC
INTRODUCTION
BREAKING IN A NEW MACHINE
Your machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe
conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break in the machine
for the initial 100 hours, as indicated by the service meter.
During breaking in:

• After starting, let the engine idle for five minutes to allow proper engine warm up prior to actual operation.
• Avoid operation with heavy loads or at high speeds.
• Avoid sudden starts or acceleration, unnecessarily abrupt stops and sharp steering except in cases of emergency.
The precautions given in this manual for operating, maintenance, and safety procedures are only those that apply when this
product is used for the specified purpose. If the machine is used for a purpose that is not listed in this manual, KOMATSU
MINING SYSTEMS cannot bear any responsibility for safety. All consideration of safety in such operations is the
responsibility of the user. Operations that are prohibited in this manual must never be carried out under any circumstance.
PLATE LOCATIONS AND TABLE TO ENTER PIN AND DISTRIBUTOR

MACHINE PIN PLATE
The product identification number (PIN) is stamped on a plate located on
the center right of the frame.
ENGINE SERIAL NUMBER PLATE

The engine serial number and information is stamped on a plate located on
the left side air intake manifold at the flywheel end.
WA900-3LC 0-5
INTRODUCTION
TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.:
Engine serial No.:

Distributor name:
Address: Phone:
Service personnel for your machine:
0-6 WA900-3LC
INTRODUCTION
TABLE OF CONTENTS
INTRODUCTION
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
BREAKING IN A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
PLATE LOCATIONS AND TABLE TO ENTER PIN AND DISTRIBUTOR . . . . . . . . . . . . . . . 0-5
MACHINE PIN PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
ENGINE SERIAL NUMBER PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . 0-6
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
SAFETY
GENERAL PRECAUTIONS AND SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
WHEN LEAVING OPERATORS COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
FIRE PREVENTION FOR FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
PRECAUTIONS WHEN WORKING AROUND HIGH TEMPERATURES . . . . . . . . . . . . . . . . 1-5
DUST HAZARD PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
CRUSH OR PINCH POINT PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
FIRE EXTINGUISHER AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
PRECAUTIONS WHEN USING ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
PRECAUTIONS FOR ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
PRECAUTIONS WHEN HANDLING ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
INDOOR VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
INSIDE OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
CAB GLASS, WASHER FLUID AND MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
SAFETY AT THE WORK SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
BEFORE STARTING YOUR MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
WHEN STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
IN THE OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
OPERATING YOUR MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
AFTER STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
CHANGING DIRECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
PROHIBITED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
PRECAUTIONS WHEN TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
TRAVELING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
PRECAUTIONS WHEN OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
WA900-3LC 0-7
INTRODUCTION
PROPER METHOD OF USING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
OVERHEAD HIGH VOLTAGE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
OPERATING ON SNOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
OPERATING ON LOOSE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
PARKING YOUR MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
PRECAUTIONS IN COLD AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
TRANSPORTING YOUR MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
LOADING AND UNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
BATTERY MAINTAINANCE AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
CHARGING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
TOWING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
BEFORE PERFORMING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
NOTIFICATION OF FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
WARNING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
CLEANING BEFORE INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 1-22
KEEP YOUR WORK PLACE CLEAN AND TIDY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
APPOINT A LEADER WHEN WORKING WITH OTHERS . . . . . . . . . . . . . . . . . . . . . . . . 1-23
RADIATOR COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
WORK EQUIPMENT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
BEFORE CARRYING OUT INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . 1-24
PROPER TOOL USAGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
REPLACEMENT OF CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
USE OF LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
PREVENTION OF FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
DURING THE MAINTENANCE PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
PERSONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
REPAIRING ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
WORKING UNDER YOUR MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
MAINTENANCE WITH CHASSIS RAISED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
WORKING ON TOP OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
MAINTENANCE WITH ENGINE RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
PRECAUTIONS WHEN USING A HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
DROPPING TOOLS OR PARTS INSIDE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
WHEN AN ABNORMALITY IS LOCATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
HANDLING HIGH PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
SAFETY RULES TO FOLLOW WHEN ADDING FUEL OR OIL . . . . . . . . . . . . . . . . . . . 1-28
PRECAUTIONS WHEN HANDLING HIGH PRESSURE SYSTEMS . . . . . . . . . . . . . . . . 1-29
CARRYING OUT MAINTENANCE AT HIGH TEMPERATURES OR
HIGH PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
MAINTENANCE OF AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
FINAL CHECKS AFTER INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . 1-30
DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
0-8 WA900-3LC
INTRODUCTION
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
HANDLING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
STORAGE OF TIRES AFTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
SAFETY LABLE LOCATONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
SAFETY LABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
OPERATION
GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

PROFILE OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
VIEW OF CONTROLS AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
OPERATORS COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
MAINTENANCE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
OVERVIEW OF COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
ALERT DISPLAY INDICATORS (B, E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
GUAGE DISPLAY SYSTEM (A, C, D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
OPTION DISPLAY SYSTEM (F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
TESTING MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
WARNING DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
CENTRAL LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
CHECK LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ENGINE COOLANT LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ENGINE OIL LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
BRAKE OIL PRESSURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
ENGINE OIL PRESSURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
BATTERY CHARGE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
AIR CLEANER RESTRICTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
TRANSMISSION OIL FILTER LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
GROUND DRIVEN STEERING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
ECM DIAGNOSTIC WARNING LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
METER DISPLAY PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
SYSTEM INDICATOR LAMPS AND GUAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
PARKING BRAKE LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
PREHEATING AND AFTER HEATING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
FRONT WORK LAMP INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
REAR WORK LAMP INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
TRANSMISSION CUT OFF INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
TURN SIGNAL INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
TRANSMISSION SHIFT SELECTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
ENGINE COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
TORQUE CONVERTER TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
SERVICE HOUR METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
TRANSMISSION SHIFT INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
WA900-3LC 0-9
INTRODUCTION
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
TRANSMISSION CUT OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
FRONT WORK LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
REAR WORK LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
TRANSMISSION MANUAL SELECTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
LAMP SWITCH AND TURN SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
HAZARD LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
FRONT WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
REAR WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
ECM ON/OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
ECM SELECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
CIGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
JOYSTICK STEERING ON/OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
JOYSTICK STEERING LEVER SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
STEP LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
CAB LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
POWER WINDOW SWITCHES (RIGHT and LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
MULTIPLE USE TOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
MULTIPLE USE SIDE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
ENGINE LOW IDLE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
AUTO GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
CONTROL LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
SPEED CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
DIRECTIONAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
SPEED CONTROL LEVER LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
SAFETY LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
BUCKET CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
BOOM CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
BRAKE PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
JOYSTICK STEERING LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
ENGINE CONTROL MODULE (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
ON/OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
ECM DIAGNOSTIC WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
ENGINE FAULT DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL . . . . . . . . . . . . . . . . 2-33
EXPLANATION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
COOL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
AM/FM STEREO CASSETTE RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
EXPLANATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
EXPLINATION OF OPERATION METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
PRESETTING TO SELECTED STATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
AUTO MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
RECEIVING RADIO BROADCASTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
AUTOMATIC TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
MANUAL TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
0-10 WA900-3LC
INTRODUCTION
SELECTION BETWEEN MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
ADJUSTING TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
PLAYING A CASSETTE TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
CHANGING TAPE CHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
FAST FORWARDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
REWINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
PRECAUTIONS WHEN USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
JOYSTICK STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
EXPLANATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
STRUCTURE AND FUNCTION OF JOYSTICK STEERING SYSTEM . . . . . . . . . . . . . . 2-49
OPERATION OF JOYSTICK STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
ADJUSTMENT OF STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
JOYSTICK STEERING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
JOYSTICK CONSOLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
AUTO SHIFT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
METHOD OF OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
PRECAUTIONS WHEN CHANGING DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
MAIN MONITOR FAILURE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
MAIN MONITOR DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
ERROR CODES INDICATED ON MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
STEERING COLUMN TILT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
CAP LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
OPENING AND CLOSING CAPS WITH LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
SAFETY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
BACKUP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
DOOR OPEN LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
TOOL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
FUEL STOP LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
SLOW BLOW FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
FUSE CAPACITY AND CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
LUNCH BOX TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
MANUAL STORAGE PLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
24V POWER FOR ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
12V POWER FOR ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
PRECAUTIONS WHEN HANDLING ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
CHECKS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
CHECKS BEFORE STARTING YOUR WORK CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
CHECKS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
OPERATIONAL CHECKS AFTER STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
MOVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
CHANGING GEAR SPEED RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
CHANGING DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
STOPPING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
WA900-3LC 0-11
INTRODUCTION
OPERATION OF WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
TYPICAL WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
PRECAUTIONS FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
ADJUSTING WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
CHECKS AFTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
STOPPING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
CHECKS AFTER STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
LOCK AND SECURE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
HANDLING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
BUCKET REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
LIFTING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
PRECAUTIONS FOR LOW TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
PRECAUTIONS AFTER WORK COMPLETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
AFTER COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
WARM UP OPERATION FOR HYDRAULIC STEERING CIRCUIT IN
COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
BEFORE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
DURING STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
AFTER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
WHEN MACHINE RUNS OUT OF FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
MAINTENANCE ON A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
IF BATTERY IS DISCHARGED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119
MAINTENANCE
GUIDES TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

OUTLINE OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
OUTLINE OF OIL, FUEL, AND COOLANT USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
STORING OIL AND FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
PARTS WEAR LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE CHART . . . . . . . . . . . . 3-9
SELECTION OF FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
ENGINE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
ARCTIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
0-12 WA900-3LC
INTRODUCTION
TRANSMISSION, CONVERTER, TRANSFER CASE, COOLER, SERVICE BRAKES
AND HYDRAULIC SYSTEM OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
DRIVE AXLE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
DIESEL FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
SUPPLEMENTAL COOLANT ADDITIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
STANDARD TIGHTENING TORQUES FOR FASTNERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
NECESSARY MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
PERIODIC REPLACEMENT OF SAFETY RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . 3-18
CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
MAINTENANCE SCHEDULE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
SCHEDULED MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
SERVICE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
INITIAL 50 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
INITIAL 250 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
FUEL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
TRANSMISSION OIL FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
ENGINE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
CLEAN OR REPLACE AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
CLEANING COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
CHECKING TRANSMISSION OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
CHECKING AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
CHECKING AXLE CASE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
CHECKING WINDOW WASHER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
CLEANING AIR CONDITIONER CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
CLEANING RADIATOR FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
CHECKING INTAKE AIR HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
REPLACING BUCKET WEAR ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
CHECKING AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
ADJUSTING PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
BLEEDING AIR FROM BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
BLEEDING AIR FROM PPC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
BLEEDING AIR FROM HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
BLEEDING AIR FROM THE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
REPLACING SLOW BLOW FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
REPLACING FAN BELT AND AUTO TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
SELECTION AND INSPECTION OF TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
CLEANING HIGH PRESSURE STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
CHECKS BEFORE STARTING WORK CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
CHECKING MONITOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
CHECKING COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
CHECKING OIL LEVEL IN ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
CHECKING BRAKE OIL TANK LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
WA900-3LC 0-13
INTRODUCTION
CHECKING FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CHECKING ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CHECKING TIRES INFLATION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
CHECKING EFFECT OF PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
CHECKING EFFECT OF BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
EVERY 50 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
EVERY 100 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
CHECKING OIL LEVEL IN HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
AIR CONDITIONER FRESH AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
CHECKING BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
CHECKING ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
AIR CONDITIONER RECIRCULATION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
CHECKING REFRIGERENT COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . 3-57
CHECKING FOR LOOSE WHEEL HUB NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
CHECKING FRAME AND BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
CHANGING ENGINE OIL AND FILTER CARTRIDGES . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
REPLACING FUEL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
REPLACING TRANSMISSION OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
LUBRICATE CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
CHECKING FAN BELT FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
EVERY 1000 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
CLEANING TRANSMISSION CASE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
CHECKING PARTS OF TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
CLEANING FUEL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
CHECKING ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
CORROSION RESISTANCE CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
CHANGING HYDRAULIC OIL AND FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . 3-76
CLEANING HYDRAULIC TANK STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
REPLACING HYDRAULIC TANK VENT ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
CHANGING AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
REPLACING AIR CONDITIONER CAB FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
CLEANING PPC CIRCUIT STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
CHECKING WEAR ON BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
CHECKING ALTERNATOR AND STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
CHECKING ENGINE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
CHECKING TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
CHECKING PLAY OF TURBOCHARGER ROTOR SHAFT . . . . . . . . . . . . . . . . . . . . . . . 3-86
CHECKING ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
CHECKING WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
CHECKING ENGINE VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
CHECKING FAN AND TENSIONER PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
SPECIFICATIONS
0-14 WA900-3LC
INTRODUCTION
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
OPTIONS, ATTACHMENTS
OPTIONAL PARTS AND ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

SELECTING BUCKETS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
AUTO GREASING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
METHOD OF OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
PRECAUTIONS WHEN HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
ADJUSTING DISCHARGE FROM INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
METHOD OF SETTING TIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
WA900-3LC 0-15
INTRODUCTION
0-16 WA900-3LC
1SAFETY
WARNING!
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.
This safety section also contains precautions for optional
equipment and attachments.
WA900-3LC 1-1
SAFETY
GENERAL PRECAUTIONS AND SAFETY RULES
GENERAL SAFETY RULES

Only trained and authorized personnel shall be allowed to operate and service this machine.
Before operating this machine it is important to study the operators manual thoroughly and become familiar with all
controls and safety decals. Keep this manual with your machine at all times for easy reference.
Safety must always be the operators most important concern. Never operate a machine that is unsafe or in poor operating
condition.
Always perform a pre-operational check on your machine before operating it.
If the machine is equipped with a seat belt and rollover protective structure, OSHA law requires the operator remain within the
confines of the rollover protective structure, with the seat belt fastened snugly around their waist before
operating the machine.
OSHA law states if your equipment is designed for operation by one person, it is for one person only, never allow other
personnel to ride on your machine.
Never leave your machine running and unattended. Always park the machine in a level area, lower any work equipment to the
ground, set the parking brake and turn the engine off before exiting the operators compartment.
Be sure that all personnel are at least 12 m (40 ft) away from any point on the machine before moving the machine. Never
allow anyone to stand near the machine while in operation. Remember, the larger the machine the more restricted your
visibility will be.
If pedestrians are in the area proceed slowly and sound your horn. Keep in mind, pedestrians have the right away, and a loaded
or smaller machine has the right away over an unloaded machine.
Never use your machine for tasks it was not designed for, damage to the machine or injury to the operator may result.
Follow all safety rules, precautions, and instructions when operating or performing maintenance on the machine.
It is the owner and /or operators responsibility to replace any safety or warning decals if they are defaced or removed from the
machine.
Think before you act, study the job carefully. Careful operators and service personnel are the best insurance against
accidents.
The operator of this machine must be alert, physically fit, and free from the influences of alcohol, drugs or medications that
might affect there eyesight, hearing, or reactions.
When working with another person on a work site, or during traffic control, be sure all personnel involved understand all hand
signals that are to be used.
Follow all rules relating to safety as outlined in this manual and by your company, never get involved in horseplay.
1-2 WA900-3LC
SAFETY
SAFETY FEATURES
Be sure all guards and covers are in place especially after servicing the machine.
Have guards or covers repaired immediately if they are damaged.
Use safety equipment such as safety lock lever (1) and seat belt
properly.
Never remove any safety features. Always keep them in good

operating condition.
Safety lock lever: See “PARKING THE MACHINE” on page 2-101.
Seat belt: See “SEAT BELT” on page 2-79.
Improper use of safety features could result in serious bodily injury or death.
Be sure the machine has the correct equipment required by local rules and regulations.
CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT

If your machine is equipped with safety equipment OSHA law requires
this equipment be used when operating your machine.
Avoid loose fitting clothing, jewelry and loose long hair. These can catch
on controls or in moving parts and cause serious injury or death.
Wear a hard hat, safety glasses, safety shoes, mask or gloves when
operating or maintaining the machine. Always wear safety goggles,
hard hat and heavy gloves, if your job involves driving pins with
a hammer or cleaning the air cleaner element with compressed air.
Also, check to be sure no one is near your work area.
Check to be sure all personal protective equipment are in good condition

before using.
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization from Komatsu can create a hazards. Before making any modifications, consult
your local distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modifications.
WA900-3LC 1-3
SAFETY
WHEN LEAVING OPERATORS COMPARTMENT
Never leave your machine running and unattended. Always park the machine in a level area, lower work equipment to the
ground, set the parking brake and turn the engine off before exiting the operators compartment.
When exiting the operator’s compartment, lower the work equipment completely to the ground, set the safety lock lever to the
LOCK position, then stop the engine. Always take the key with you. Place the safety lock lever (1) securely in the LOCK
position and set the parking brake switch (2) in the ON position. Use the key to lock all the equipment locks. If you
accidentally touch the transmission or equipment levers when they are not locked, the machine or work equipment may move
and cause serious injury or damage.
Work equipment posture: See “PARKING THE MACHINE” on page 2-101.

Lock: See “LOCK AND SECURE LOCATIONS” on page 2-104.
MOUNTING AND DISMOUNTING

Use all hand holds and step plates on your machine. Be sure to maintain a 3 point contact
when entering or exiting your machine at all times. Never jump off or on to your machine..
Before getting on or off the machine, if there is any oil, grease, or mud on your shoes, rails, steps
or platforms, wipe it off immediately, always keep these areas clean, and in good condition.
Never jump on or off the machine. Never get on or off a moving machine. These actions may
lead to serious injury. Be sure machine is at a full stop, equipment lowered and parking brake set
before entering or exiting machine.
When getting on or off the machine, always face the machine and maintain three point contact (both feet and one hand or one
foot and both hands) with the handrails, steps and platforms to ensure that you support yourself securely.
Never hold any control levers when getting on or off the machine. When opening the cab door, stand on the top stair.
Never step down from a step at the rear of the machine or from the side of the cab to a tire. Use the points marked by arrows in
the diagram when getting on or off the machine.
1-4 WA900-3LC
SAFETY
.
FIRE PREVENTION FOR FUEL AND OIL

Fuel and oil are flammable. Fuel is particularly flammable and can be hazardous. Always observe the following:
• Keep any open flames away from flammable fluids.

• Stop the engine and do not smoke when refueling.
• Tighten all fuel and oil caps securely.
• Refueling and oiling should be made in well ventilated areas.
• Keep oil and fuel in its proper place and do not allow unauthorized persons to enter.
• Clean up all spills.
PRECAUTIONS WHEN WORKING AROUND HIGH TEMPERATURES

Immediately after operations are stopped, the engine coolant, engine oil and hydraulic oil are at high temperatures and are still
under pressure. Attempting to remove the radiator cap, drain the oil or coolant or replace the filters may lead to serious burns.
Always wait for the temperature to go down and follow the specified procedures when carrying out these operations:
To prevent hot coolant from spurting out and burning you:
• Turn the engine off.

• Allow coolant to cool.
• Slowly loosen cap to relieve pressure before removing.
To prevent hot oil from spurting out and burning you:

• Turn the engine off.
• Allow oil to cool.
• Slowly loosen cap to relieve pressure before removing.
WA900-3LC 1-5
SAFETY
DUST HAZARD PREVENTION
Dust can be hazardous to your health if it is inhaled. Komatsu Mining Systems does not use asbestos in its products, but if you
handle materials containing asbestos fibers or other dust materials during demolition operations, always do as follows.
• Never use compressed air for cleaning.

• Use water to keep down the dust when cleaning.
• If there is a danger there may be asbestos dust in the air, operate the machine
with the wind to your back whenever possible.
• Use an approved respirator.
• Do not allow any other person into the area during operation.
• There may be a danger that non genuine parts may contain asbestos, use only genuine
Komatsu parts.
• Always observe rules and regulations related to the job site and working environment.
CRUSH OR PINCH POINT PREVENTION

Never stand under or place any part of your body between the movable components such as the work equipment and cylinders
or between the machine and work equipment. When the work equipment is operated, the clearance will change, this may lead
to serious personal injury or death.
FIRE EXTINGUISHER AND FIRST AID KIT

As a precaution if any injury or fire should occur, always keep a fire extiguisher and first aid kit on your machine and do as
follows:
• Be sure that fire extinguishers are in good condition and read the labels to ensure
you know how to use them.
• Provide a first aid kit at the storage point. Check the kit periodically and make any
additions if necessary.
• Know what to do in the event of injury or fire.
• Make a list of the phone numbers of persons you should contact in case of an
emergency (doctor, ambulance, fire station) and post the list at specified places to
ensure all workers can carry out the emergency contact.
1-6 WA900-3LC
SAFETY
PRECAUTIONS WHEN USING ROPS
The ROPS (Roll Over Protective Structure) must never be removed from the machine. The ROPS is installed to
protect the operator if the machine should roll over. It is designed not only to support the load if the machine should roll over,
but also to absorb the impact of the energy.
The ROPS fulfills all the regulations and standards for all countries, but if it is rebuilt without authorization or is damaged
when the machine rolls over, the strength may be reduced and not able to fulfill its function properly.
When modifying or repairing the ROPS, always contact your Komatsu distributor.
Even if the ROPS is installed, it cannot provide the full protection if the operator does not fasten the seat belt properly. Always
fasten your seat belt when operating the machine.
PRECAUTIONS FOR ATTACHMENTS

When installing and using an optional attachment, read instruction manual for the attachment and information related to
attachments in this manual.
Do not use attachments that are not authorized by your distributor or Komatsu Mining Systems. Use of unauthorized
attachments could create a safety problem and adversely affect proper operation and useful life of the machine.
Any injuries, accidents, product failures resulting from use of unauthorized attachments will not be the responsibility of
Komatsu.
PRECAUTIONS WHEN HANDLING ACCUMULATOR

If the travel damper (ECSS) switch is turned ON when the machine is traveling or when the work equipment is raised, the
hydraulic accumulator in the travel damper will instantaneously be connected with the boom cylinder bottom circuit. Be
careful when doing this, because the oil will then flow in or out in the direction to balance oil pressure at the accumulator and
boom cylinder bottom and the work equipment will move.
• When releasing the pressure or charging with gas for the work equipment circuit of machines equipped with an
accumulator, be careful and follow the instructions given for handling the accumulator.
• The accumulator is charged with high pressure nitrogen gas which is extremely dangerous, read the following items and
be careful to handle the accumulator properly.
• Do not make any holes or bring any open flames or heat close to the accumulator.
• Do not weld any bosses to the accumulator.
• The gas must be released before disposing of the accumulator, ask your distributor to do this for you.
INDOOR VENTILATION
When starting the engine or using fuel, flushing oil or painting indoors or in areas with poor
ventilation, always open the windows and doors to improve the ventilation and prevent the danger
of gas poisoning.
If the ventilation is still insufficient even when the windows and doors are opened, use a
ventilation fan.
WA900-3LC 1-7
SAFETY
INSIDE OPERATOR’S COMPARTMENT
When entering the operator’s compartment, always remove mud and oil from the soles of your shoes. If you operate the brake
pedal with mud or oil stuck to your shoes, your foot may slip and may cause an accident.
After using the ashtray, make sure matches or cigarettes are properly extinguished and be sure to close the lid. If the ashtray is
left open, there is danger of fire. Do not leave lighters lying around the operator’s compartment. If the temperature inside the
operators compartment become high, there is danger that the lighter may explode.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not use cellular telephones inside the operator’s compartment when driving or operating the machine.
Never bring any dangerous objects such as flammable or explosive items into the operator’s cab.
To ensure safety, do not use the radio or music headphones when operating the machine.
Keep the operator’s compartment clean, never allow trash or tools to accumulate, these may hinder the operation of the
controls or pedals.
When operating the machine, do not put your hands or head out of the window.
CAB GLASS, WASHER FLUID AND MIRRORS

If the cab glass on the work equipment side should break, there is a danger you may come in direct contact with the work
equipment. If the glass breaks, stop operation immediately and replace glass.
Use automotive type washer fluid in washer reservoir. Do not use flammable fluids in the cab glass washer system.
Remove all dirt from the surface of the windows and lights to ensure that you can see well. Adjust the side mirror so you can
see clearly from the operators seat and always keep the surface of the mirror clean. If any glass is broken, replace it with a new
part.
1-8 WA900-3LC
SAFETY
PRECAUTIONS DURING OPERATION
BEFORE OPERATING THE MACHINE

SAFETY AT THE WORK SITE
Before entering the operators compartment, walk completely around the machine and clear the area of personnel and
obstructions.
• Before starting your machine, thoroughly check the area for any unusual conditions that could be dangerous.
• Before starting your machine, examine the terrain and soil conditions of the work
site. Determine the best and safest method of operation.
• If you need to operate on a street, protect pedestrians and cars by designating
a person for work site traffic duty or by installing barriers around the work site.
• If water lines, gas lines, telephone lines and high voltage electrical lines may be
buried under the work site, contact each utility and identify their locations. Be
careful not to sever or cut any of these lines.
• Check the depth and flow of water before operating in water or crossing a river.
• Never be in water which is in excess of the permissible water depth. See “PRECAU-
TIONS FOR OPERATION” on page 2-97.
BEFORE STARTING YOUR MACHINE

Perform the following checks before starting your machine at the beginning of each work day. Failure to perform these checks
may lead to serious injury or damage.
• Completely remove all wood chips, leaves, grass, paper and other flammable
materials accumulated in the engine compartment and around the battery. Check
fuel, lubrication and hydraulic systems for leaks and have any leaks repaired. Wipe
up any excess oil, fuel or other flammable fluids. Return all fuel containers to their
proper place, remove all parts and tools from the operators compartment and remove
any dirt from the mirrors, handrails and steps.
Check points: See “CHECKS BEFORE OPERATING THE MACHINE” on page 2-69.
• Check the coolant level, fuel level and oil level in the engine oil pan, check for
clogging of the air cleaner and check for damage to the electric wiring.
Starting: See “CHECKS BEFORE STARTING THE ENGINE” on page 2-80.
• Adjust the operators seat to a position where it is easy to carry out operations and
check for wear or damage to the seat belt and seat belt mounting equipment.
Adjusting operators seat: See “OPERATOR’S SEAT” on page 2-77.
Handling seat belts: See “SEAT BELT” on page 2-79.
• Check to be sure the gauges work properly and the control levers are in the parked position.
• Checking operation of gauges: See “CHECKS BEFORE OPERATING THE MACHINE” on page 2-69.
• Remove all dirt from the surface of the window glass and lights to ensure good visibility.
• Adjust the side mirror to a position which gives the best view from the operators seat and clean the surface of the mirror.
If the mirror glass is damaged, replace it.
• Check the operation of the front lamps and working lamps. If the results of the inspection show any abnormality, always
carry out repairs.
• Before starting the engine, check to be sure the safety lock is at the LOCK position.
• Be sure a fire extinguisher is installed and in working condition. Do not operate the machine near any fire or flames.
WA900-3LC 1-9
SAFETY
WHEN STARTING ENGINE
Walk around the machine again just before mounting it and check for people or objects that might be in the way.
• Never start the engine if a warning tag has been attached to control lever.
• When starting the engine, sound the horn as an alert.
• Start and operate the machine only while seated.
• Do not allow anyone to ride on your machine.
• Do not start the machine by shorting the starter motor circuit. This operation is dangerous and may damage the machine.
• If a back up alarm is installed, make sure it works normally.
IN THE OPERATOR’S CAB

• Do not leave tools, spare parts or personal items lying around in the operators
compartment. They may damage, break or jam the control levers or switches.
Always put them in their proper place.
• Keep the cab floor, controls, steps and handrails free of oil, grease, snow and excess
dirt.
• Check the seat belt, buckle and hardware for damage or wear. Replace any worn or
damaged parts. Never use bleach, dye or solvents on the seat belt this may
weaken the webbing and result in personal injury. Clean the seat belt with warm
water and a mild detergent. Always use seat belts when operating your machine.
• Never steam clean or pressure wash the interior of the operators cab.
See “SEAT BELT” on page 2-79.
• Do not service the air conditioning system unless you are been licensed.
• Know your alternate exit routes from the operators compartment for use in an emergency.
1-10 WA900-3LC
SAFETY
OPERATING YOUR MACHINE
AFTER STARTING THE MACHINE
Failure to carry out the checks properly after starting the engine will lead to delays,
injury or damage to you or the machine. When carrying out the checks, use a wide
area where there are no obstructions.
• Do not allow anyone near the machine.
• Check operation of the gauges, equipment, bucket, boom arm, brakes, travel
system and steering system.
• Checks for any abnormality in the sound of the machine, vibration, heat,
odor, check for leakage of air, oil or fuel. If any abnormality is found, carry
out repairs immediately.
• If the machine is used when it is not in proper operating condition, this may lead
to serious injury or damage to the machine.
• Before traveling or starting operations, check the safety bar is securely locked in the FREE position.
• Before starting, check to be sure no one is in the surrounding area and that there are no obstacles.
• When starting, sound the horn as an alert.
• Always operate the machine only when seated in the operators seat. Always fasten the seat belt.
• Do not allow anyone to ride on the machine.
• Check to be sure the backup alarm works properly.
CHANGING DIRECTIONS
To prevent serious injury or death, always do the following before moving the machine or the work equipment.
• Sound the horn to warn people in the area.
• Check to be sure there is no one near the machine. Be particularly aware of
people behind the machine, this area cannot be seen from the operators seat.
• When operating in the areas that may be hazardous or have poor
visibility, designate a person to direct work site traffic.
• Ensure that no unauthorized person can come within the direction of
turning or direction of travel.
• Always be sure to carry out the above precautions even when the machine
is equipped with a backup alarm and mirrors.
PROHIBITED OPERATION
To prevent the machine from turning over or the work equipment from being damaged because of overload, always stay within
the maximum load specified for the machine. Never use the machine in excess of its capacity.
Never use your machine for operations it was not designed for, damage to the machine or injuries to you or others may result.
WA900-3LC 1-11
SAFETY
PRECAUTIONS WHEN TRAVELING
Never turn the ignition switch to the OFF position when traveling. If the engine stops when the machine is traveling, the
steering will become heavy. Apply the brakes immediately to stop the machine.
Keep your mind on what your are doing at all times. Always concentrate on your work.
Never drive up to, back up to, or allow anyone to stand or park in front or behind your machine.
Travel at a safe speed, avoid sudden starts or stops. Never turn sharply or zigzag your machine. If you find any abnormality in
your machine during operation (noise, vibration, smell, incorrect gauges, air leakage, oil leakage, etc.), immediately move
your machine to a safe place, shut it down and investigate the cause.
Travel with the work equipment at a height of: (A) 72 to 85 cm (28 to 34 in.) from the ground, and travel on level ground.
Never travel with the work equipment (loaded or unloaded) raised too high. This will effect the machines center of gravity
When traveling, do not operate the work equipment control levers. If the levers have to be operated, stop the machine first,
then operate the levers.
Do not turn the steering wheel suddenly. The work equipment may hit the ground, damage the machine or structures in the
area.
When traveling on rough ground, travel at low speed and avoid sudden changes in direction.
Avoid running over obstacles. If the machine has to travel over an obstacle, keep the work equipment as close to the ground as
possible and travel at low speed.
When traveling or carrying out operations, always maintain a safe distance from other machines or structures to avoid coming
into contact with them. Be sure operators of the other equipment around you are aware of your presence and able to clearly see
you, wave or signal to them to be sure they see you and are aware of your presence.
Never travel in water which exceeds the permissible water depth specified in this manual. Permissible water depth: See “PRE-
CAUTIONS FOR OPERATION” on page 2-97.
When traveling on bridges, structures or support surfaces, check the structure or surface first to be sure it is strong enough to
support your machine. When traveling on public roads, check with the local authorities first and follow their instructions.
Always obey the traffic regulations when traveling on public roads. This machine travels at a slower speed than automobiles,
keep to the side of road.
1-12 WA900-3LC
SAFETY
If you drive your machine at high speeds continuously for a long time, the tires will overheat. This may cause the tires to burst.
If a tire should burst, it will produce an extremely destructive force, this may cause serious injury or accident.
If you must travel continuously, consult your distributor first.
TRAVELING ON SLOPES
Due to the high center of gravity on the machine, the danger of traveling on slopes could cause the machine to rollover, tip or
slide.
When traveling on slopes, keep the bucket approximately 20 to 30 cm (8 to 12 in) above the ground. In case of an emergency,
quickly lower the bucket to the ground to help stabilize or stop your machine.
Never turn, maneuver or travel across a slopes. Make all turns or maneuvers on level ground.
Avoid traveling on grass, fallen leaves, or wet steel plates. Even slight slopes with these objects may cause your machine to
slide. Travel at low speed and make sure your machine is always traveling directly up or down the slope.
When traveling downhill, never shift gears or place the transmission in neutral. Use the braking force of the engine together
with the brake pedal to control the travel speed of your machine. Always place the transmission in a low gear before
traveling downhill.
If the engine should stop when the machine is on a slope, immediately depress the brake pedal to apply the brakes, (do not
pump the brakes) lower the bucket to the ground, then apply the parking brake to hold the machine in position.
When traveling up or down hills with a loaded bucket, always travel with the bucket facing uphill (travel forward when going
uphill and in reverse when going downhill). Never travel with the bucket facing downhill (loaded or unloaded). This may
cause your machine to tip forward rasing the rear wheels off the ground.
WA900-3LC 1-13
SAFETY
PRECAUTIONS WHEN OPERATING
• Be careful around open trenches or cliffs. Always approach these areas with caution.
• Always travel on level ground with the load 40-50 cm (16-20 in) above the ground.
• When traveling on embankments, landfills or when dropping soil over a cliff, dump one pile, then use the next pile of soil
to push the first pile.
• The load will becomes lighter when the soil is pushed over a cliff or when the machine reaches the top of a slope. When
this happens, there is danger the travel speed will suddenly increase, be sure to reduce your speed.
• When the bucket is fully loaded, avoid fast starts, sharp turns or sudden stops. This may cause your machine to tip.
• When handling awkward loads, such as round or cylindrical objects, piled scrap, or timber if the work equipment is raised
too high, there is danger the load may fall on to the operator’s compartment and cause serious injury or damage.
.
• When handling unstable loads, be careful not to raise the work equipment too high or tip the bucket back too far.
• If the work equipment is lowered quickly and suddenly stopped, the reaction may cause the machine to rock.
• When your work equipment is loaded operate it carefully.
• Never use the bucket or boom arm as a crane, drag line or hoist. Use your work equipment only for the specified purpose
designated in this manual for your machine. Carrying out non-approved operations will cause breakdowns or possible
injuries. See “TYPICAL WORK OPERATIONS” on page 2-93.
• When operating in dark places, use the work lamps and install additional lighting at the job site if necessary.
• Do not operate machine in fog, mist, snow, heavy rain or conditions where visibility is poor. Wait for the weather to clear
so visibility is sufficient to carry out work.
• When operating in areas where overhead clearances are limited, be extremely careful not to let the bucket or operators cab
hit anything.
• When loading dump trucks, be sure all personnel are clear of the work area, be careful not to let the bucket hit the
operators compartment of the dump truck.
• Always operate your machine at a safe speed, particularly in confined spaces, indoors or in places where there are other
machines. Always maintain a safe clearance around your machine and other objects.
1-14 WA900-3LC
SAFETY
PROPER METHOD OF USING BRAKES
Do not travel with your foot on the brake pedal.
Do not pump the brake pedal repeatedly unless necessary.
When traveling downhill, use the engine as a brake and always use the right brake pedal.
OVERHEAD HIGH VOLTAGE CABLES

Do not let your machine come in contact with overhead high voltage cables. Even operating close to high voltage cables can be
dangerous. Always maintain a safe distance given below between the machine and the high voltage cables.
To help prevent accidents, always follow the procedures listed below:
• On job sites where there is a present danger the machine may come in contact with the high voltage cables, consult the
local power company before starting any operations. Be sure proper safety actions have been determined by the local laws
and regulations set forth by the power companies.
• Wear rubber souled shoes and gloves. Lay a rubber sheet on top of the operators seat and be careful not to touch the
chassis with any exposed part of your body.
• Use a signalman to warn you if the machine approaches any high voltage cables.
• If your equipment should touch a high voltage cable, the operator should remain in the operator’s compartment.
• When carrying out operations near high voltage cables, do not let anyone come close to your machine.
• Check with the power company before starting any operations near high voltage cables.
Voltage Minimum Safe

Distances
100 to 200 V 2m 7 ft
Voltage
Low
6600 V 2m 7 ft
22000 V 3m 10 ft
66000 V 4m 14 ft
Very High Voltage
154000 V 5m 17 ft
187000 V 6m 20 ft
275000 V 7m 23 ft
500000 11 m 36 ft
WA900-3LC 1-15
SAFETY
OPERATING ON SNOW
When operating on snow or icy roads, always travel at low speed and avoid sudden starting, stopping, turning, or
traveling downhill.
When operating on frozen road surfaces, the ground becomes soft when the temperature rises, the travel conditions become
unstable.
After heavy snows, the road shoulder and objects placed beside the road are buried in the snow and cannot be seen, always
carry out snow clearing operations carefully.
When traveling on snow covered roads, always use tire chains if possible.
When traveling on snow covered slopes, never apply the brakes suddenly. Reduce the speed and use the engine as a brake
while applying the foot brake intermittently (depress the brake intermittently several times). If necessary, lower the bucket to
the ground to stop the machine.
The load will vary greatly according to the characteristics of the snow, so adjust the load accordingly and be careful not to let
the machine slip.
OPERATING ON LOOSE GROUND

Do not operate your machine on soft ground. Due to the machines weight it could get stuck.
Avoid operating your machine close to cliffs, overhangs or trenches. These areas could collapse under the vibration or weight
of your machine. Remember after a heavy rain, blasting or earthquakes soil is weakened in these areas.
Freshly laid soil near roads, pipelines or ditches are soft and loose. This soil can collapse under the vibration of your machine
and cause tipping or a rollover.
Install the over head guard when working in areas where there is danger of falling stones or rocks.
1-16 WA900-3LC
SAFETY
PARKING YOUR MACHINE
Park the machine on level ground where there is no danger of falling rocks, landslides or flooding land.
If it is necessary to park the machine on a slope, set blocks under the wheels to prevent the machine from moving, then dig the
work equipment into the ground.
When parking on public roads, provide fences, signs, flags or lights and any other necessary signs to ensure that passing traffic
can see the machine clearly. Park the machine so the machine, flags and fences do not obstruct traffic. See “PARKING THE
MACHINE” on page 2-101.
When leaving the machine unattended, lower the bucket completely to the ground, set the safety lock to the LOCK position
and parking brake switch (2) to the ON position, stop the engine and lock all the equipment. Always remove the key and take
it with you.
Work equipment posture: See “PARKING THE MACHINE” on page 2-101.

Places to lock: See “LOCK AND SECURE LOCATIONS” on page 2-104.
PRECAUTIONS IN COLD AREAS

After completing operations, remove all water, snow or mud stuck to the wiring
harness, connectors, switches or sensors and cover these parts. If the water freezes, it
may cause a malfunction. Which may lead to unexpected failures.
Carry out the warming up operation thoroughly. If the machine is not thoroughly
warmed up before the control levers are operated, the reaction of the machine will be
slow which may lead to an unexpected accident.
Operate the control levers to warm up the oil in the hydraulic circuit. This ensures a good
response from the machine and prevents malfunctions during cold operations.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. The battery may
explode.
When charging or starting the engine with a different power source, warm the battery electrolyte and check for leakage of
battery electrolyte before starting.
For battery charge rate: See “IF BATTERY IS DISCHARGED” on page 2-116.
WA900-3LC 1-17
SAFETY
TRANSPORTING YOUR MACHINE
LOADING AND UNLOADING
Loading and unloading: See “TRANSPORTATION” on page 2-109.
SHIPPING
When shipping portions of the machine on a transport vehicles, obey all state and local laws governing the weight, width and
length of the load. Also obey all applicable traffic regulations.
Take into account the width, height and weight of the loads when determining the shipping route. For height, width, load of
machine: See “TRANSPORTATION” on page 2-109.
When crossing bridges or structures on private land, check to be sure the structure is strong enough to support the weight of the
machine. When traveling on public roads, check first with the local authorities and follow their instructions.
The machine can be divided into parts for transportation, when transporting the machine, contact your distributor to have the
work carried out.
1-18 WA900-3LC
SAFETY
BATTERY MAINTAINANCE AND PRECAUTIONS
SAFETY PRECAUTIONS
Battery electrolyte contains sulfuric acid and batteries generate hydrogen gas, improper handling can lead to serious injury or
fire. Observe the following precautions:
• Never smoke or allow an open flame near a battery.

• When working with batteries, always wear safety glasses and rubber gloves and
apron.
• If you spill acid on your clothes or skin, immediately flush the area with large
amounts of water.
• Battery acid could cause blindness if splashed into the eyes. If acid gets in your
eyes, flush them immediately with large quantities of water and see a doctor
immediately.
• If you accidentally drink electrolyte, drink large quantities of water or milk, beaten
egg or vegetable oil. Call a doctor or poison prevention center immediately.
• Before working with batteries, stop the engine and turn the ignition switch to the
OFF position.
• Avoid short circulating the battery terminals (between the positive and negative
terminal) through accidental contact with metal objects, such as tools.
• When installing the battery, connect the positive terminal first and when removing
the battery, disconnect the negative terminal (ground side) first.
• When removing or installing, check to be sure the positive and negative terminals
are correct and tighten the cable nuts securely.
• If the battery electrolyte level is low, add distilled water. Do not over fill battery.
• When cleaning the top surface of the battery, wash with baking soda and rinse with
water. Never use gasoline, thinner, flammable solvents or caustic cleaning agents.
• Tighten the battery caps securely.
• If the battery electrolyte is frozen, do not charge the battery or start the engine with
an auxiliary power source. This may cause the battery to explode.
• When charging or starting the engine with an auxiliary power source, thaw the
battery electrolyte first if it is frozen and check for leakage of electrolyte before
starting.
• Always remove the battery from the chassis before charging it. Never pry or
hammer on the battery terminals.
WA900-3LC 1-19
SAFETY
STARTING WITH BOOSTER CABLES
Be careful when connecting the booster cables, be sure positive cable goes to positive terminal and negative cable goes to
negative terminal. Failure to do so may cause an explosion, always do as follows:
• Carry out the starting operation with two workers (one worker sitting in the operators seat).
• When starting using another machine, do not allow the two machines to touch.
• When connecting the booster cables, turn the ignition switch OFF on both machines.
• Be sure to connect the positive cable first when installing the booster cables. Disconnect the ground or negative cable first
when removing them.
• When making the final connection, connect the ground cable to the engine block on the problem machine as far from the
battery as possible. This will prevent sparks produced during the connection from coming in contact with the battery.
CHARGING BATTERY
If the battery is handled incorrectly when it is being charged, there is danger the battery may explode, follow the instructions in
“IF BATTERY IS DISCHARGED” on page 2-116 and in the instruction manual for the charger and always observe the fol-
lowing precautions:
Carry out the charging in a well ventilated area. This disperses the hydrogen gas and prevents accumulation or explosion.
Set the voltage on the charger to match the voltage on the battery to be charged. If the voltage setting is incorrect, it may cause
the battery to overheat and catch fire.
Connect the positive charging clip of the charger to the positive terminal of the battery, then connect the negative charging clip
to the negative terminal of the battery. Be sure connection is secure, then turn the charger ON.
If battery is a maintenance free (sealed battery) do not pry off battery caps. If it is a non-maintenance free battery, remove bat-
tery caps and cover battery fill ports with a damp disposable cloth.
If the battery charge is less than 1/10 of the rated charge and high speed charging is carried out, set charger to a value below the
rated capacity of the battery. If there is an excessive flow of charging current, it may cause electrolyte to boil, which may cause
an explosion.
1-20 WA900-3LC
SAFETY
TOWING
TOWING PRECAUTIONS
Injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection of the wire rope,
always do as follow:
Follow all towing procedures outlined in this manual. See “TOWING THE MACHINE” on page 2-114.
• Always wear leather gloves when handling wire rope.
• When carrying out the preparation for towing with another worker, agree on signals before starting the operation.
• If the engine on the problem machine will not start or there is a failure in the brake system, contact your distributor for
repairs.
• It is dangerous to tow a machine on a slope, choose a place where there is a gradual slope. If there is no place with a
gradual slope, carry out work to make the slope as small as possible.
• If a problem machine is towed by another machine, always use a wire rope with a sufficient towing capacity for the weight
of the problem machine.
• Do not use a wire rope which has cut strands (A), kink (B) or reduced diameter (C).
• Do not stand astride the towing cable or wire rope.
• When connecting a machine that is to be towed, do not let any one come between the towing machine and the machine
that is being towed.
• Set the coupling of the machine being towed in a straight line with the towing portion of the machine and secure it in
position.
• Do not tow-start your machine.
WA900-3LC 1-21
SAFETY
MAINTENANCE PRECAUTIONS
BEFORE PERFORMING MAINTENANCE

NOTIFICATION OF FAILURE
Performing maintenance not described in this operation and maintenance manual may lead to unexpected failures. Please
contact your distributor for repairs.
WARNING TAGS
If others start the engine or operate the controls while you are performing service or lubrication, you could suffer serious injury
or death.
Always attach the warning tag to control lever (1) in the operator’s cab to alert others that you are working on the machine.
Remove the ignition key and keep it with you until maintenance has been completed.
Attach additional warning tags around the machine, if necessary. These tags are available from your distributor. (Part No.
09963-03000)
CLEANING BEFORE INSPECTION AND MAINTENANCE

Clean the machine before carrying out any inspection or maintenance. This will
ensure that maintenance can be carried out safely.
If inspection and maintenance are carried out with the machine still dirty, it will be
difficult to find the location of a problem.
When washing the machine, always do as follows:
• Wear nonslip shoes to protect yourself from slipping on the wet surface.
• When using high pressure steam, always wear protective clothing.
This will protect you from being hit by high pressure water and cutting
your skin or getting mud or dust into your eyes.
• Do not spray water directly on to the electrical system (sensors,
connectors). If water gets into the electrical system, there is a danger
that it will cause a malfunction.
• Do not pressure wash, steam clean or flood the cab interior of the
machine, damage to the interior components may result.
1-22 WA900-3LC
SAFETY
KEEP YOUR WORK PLACE CLEAN AND TIDY
Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil or other substances that will cause
a trip hazard. Always keep the work place clean and tidy to enable you to carry out operations safely. If the work place is not
kept clean and tidy, there is danger you could trip, slip, or fall and injure yourself.
APPOINT A LEADER WHEN WORKING WITH OTHERS

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow their
instructions during the operation. When working with others, misunderstandings between workers can lead to serious
accidents.
RADIATOR COOLANT LEVEL

When inspecting the radiator coolant level, stop the engine and wait for the engine and radiator to cool down.
If the radiator cap must be removed, always do as follows:
• Wait for the radiator coolant temperature to go down before checking the level.
• When checking if the coolant temperature has gone down, place your hand near the engine or radiator and check the air
temperature. Be careful not to actually touch the radiator or engine.
• Slowly loosen the cap to release internal pressure before removing the radiator cap, then remove the radiator cap slowly.
• When adding coolant, add it to the radiator.
WORK EQUIPMENT SUPPORT

When carrying out inspection and maintenance with the bucket raised, install stand (1) securely under the boom arm to prevent
the work equipment from falling. Place work equipment control lever (2) at HOLD and set safety lock lever (3) to the LOCK
position.
WA900-3LC 1-23
SAFETY
BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
When carrying out inspection and maintenance, park the machine on level ground where there is no danger of falling rocks,
landslides, or flooding, lower work equipment to the ground, stop the engine and remove ignition key.
• After stopping the engine, operate bucket control lever (1) several times to the raise and lower positions to release
remaining pressure in the hydraulic circuit, then set safety lock (2) to the LOCK position.
• Turn parking brake switch (3) to ON and apply the brake, then put blocks under the tires.
• Lock the front and rear frames with safety bar (4).
• The worker carrying out the maintenance should be extremely careful not to come in contact with moving parts.
PROPER TOOL USAGE INFORMATION

Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury. See
“NECESSARY MAINTENANCE TOOLS” on page 3-17.
REPLACEMENT OF CRITICAL PARTS

Hoses and other parts of the fuel, hydraulic and brake system are critical parts. For ensuring safety, they must be replaced peri-
odically. Never use aftermarket replacement parts, these may fail and cause serious injury.
Replacement of safety critical parts requires skill, ask your Komatsu distributor to carry out replacement.
Replace these components periodically with new ones, regardless of whether or not they appear to be defective.
These components deteriorate over time and can cause fire because of oil leakage or failure in the work equipment system.
Replace or repair any such components if any defect is found, even though they have not reached the time specified.
1-24 WA900-3LC
SAFETY
USE OF LIGHTING
When checking fuel, oil, or battery electrolyte, always use lighting with anti
explosion specifications. If such lighting equipment is not used, there is
danger of explosion.
If work is carried out in dark places without installing lighting, there is

danger of injury, always install proper lighting.
Even if it is dark, do not use an open flame instead of lighting. There is

danger of starting a fire or explosion.
When using the machine as a power supply for the lighting, follow the
instructions in this Operation and Maintenance Manual.
PREVENTION OF FIRE
There is a danger of the fuel and battery gas catching fire during maintenance, always follow the precautions below when
carrying out maintenance.
Store fuel, oil, grease and other flammable materials away from heat.
Use nonflammable materials as the flushing oil for cleaning parts. Do not use diesel, oil
or gasoline. There is danger they will catch fire.
Never smoke when carrying out inspection or maintenance.
When checking fuel, oil or battery electrolyte, always use lighting with anti-explosion
specifications.
Never use lighters or matches as a lighting means.
When carrying out grinding or welding operations on the chassis, remove flammable
materials.
Be sure that a fire extinguisher is present at the inspection and maintenance point.
WA900-3LC 1-25
SAFETY
DURING THE MAINTENANCE PROCESS
PERSONAL
Only authorized personnel can service and repair this machine. Do not allow unauthorized personnel into the area. If
necessary, employ an observer. Extra precaution should be used when grinding, welding, cutting and using a sledge hammer.
REPAIRING ATTACHMENTS
Appoint a leader before starting removal or installation operations on
attachments.
Do not allow anyone other than the workers close to the machine or
attachments.
Place attachments that have been removed from the machine in a safe
place so they do not fall.
Place a fence around the attachments and set up “No Entry” signs to
prevent unauthorized persons from coming close should be erected.
WORKING UNDER YOUR MACHINE

Stop the machine on firm, level ground and lower all work equipment to the
ground before performing service or repairs under the machine.
Always block the tires securely (1).
It is extremely dangerous to work under the machine if the tires are off the
ground and the machine is supported only by the work equipment.
Never work under the machine if the machine is poorly supported.
MAINTENANCE WITH CHASSIS RAISED

When carrying out operations with the work equipment or chassis raised,
lock the front and rear frames with the safety bar, return the control levers to HOLD, set the control lever safety lock to the
LOCK position and block the work equipment and chassis.
Block the wheels on the opposite side before jacking. Set blocks under the machine after jacking.
WORKING ON TOP OF MACHINE

When carrying out maintenance on top of the machine, make sure the footholds are
clean and free of obstructions and follow the precautions below to protect yourself from
falling:
• Do not spill oil or grease on any part of the chassis.

• Do not leave tools lying around. These could be a trip hazard.
• Watch your step when you are walking on the machine.
• Never jump from the machine.
• When getting on or off the machine, always use the steps and handrails and maintain
three point contact (both feet and one hand or both hands and one foot) at all times.
• Use protective equipment if necessary.
1-26 WA900-3LC
SAFETY
MAINTENANCE WITH ENGINE RUNNING
To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine
running, carry out the operation with at least two workers and do as follows:
• One worker must always sit in the operator’s seat and be ready to stop the engine at any time. All workers must maintain
contact with each other.
• When carrying out operations near rotating parts, there is danger of being caught in the parts, be extremely careful.
• When cleaning inside the radiator, set safety lock (1) to the LOCK position to prevent the work equipment from moving.
In addition, turn parking brake switch (2) to ON.
• Do not touch any control levers. If any control lever must be operated, always give a signal to the other workers to warn
them to move to a safe place.
• Never touch the fan blade or fan belt with any tool or any part of your body. There is danger of serious injury.
PRECAUTIONS WHEN USING A HAMMER

When working with hammers, wear protective glasses, helmet and other protective
clothing. Use a brass rod between the hammer and the object when striking with the
hammer.
If hard metal parts such as pins, edges, teeth and bearings are hit with a hammer, there
is a danger small pieces will fly off.
Never strike a hammer with another hammer. The hammers may shatter sending sharp
pieces of steel flying.
DROPPING TOOLS OR PARTS INSIDE THE MACHINE

When opening the inspection window, tank or oil filler to carry out an inspection, be careful not to drop any nuts, bolts or tools
inside the machine.
If parts are dropped into the machine, it may cause damage to the machine. If you drop any part into the machine, always be
sure to retrieve it from the machine.
When carrying out inspection, do not carry any unnecessary tools or parts in your pocket.
WA900-3LC 1-27
SAFETY
WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment.
Never use unqualified personnel to carry out welding. A qualified welder must follow the precautions given below:
• Disconnect the battery terminals to prevent explosion of the battery.

• Disconnect all computerized systems on your machine.
• Remove the paint from the place being welded to prevent gas from being generated.
• If hydraulic equipment, piping or places close to these are heated, flammable vapor or spray will be generated There is a
danger of this catching fire, avoid applying heat to such places.
• If heat is applied directly to rubber hoses or piping under pressure, they may suddenly burst. Cover them with fireproof
sheeting.
• Always wear protective clothing.
• Ensure that there is good ventilation.
• Clear up any flammable materials and make sure that there is a fire extinguisher at the workplace.
WHEN AN ABNORMALITY IS LOCATED

If any abnormality is found during inspection, always carry out repairs. If the machine is in use when an abnormality occurs in
the brakes or work equipment systems, it may lead to serious accident. Stop the machine immediately and secure it safely.
Depending on the type of failure, contact your distributor for repairs.
HANDLING HIGH PRESSURE HOSES

Do not bend high pressure hoses or hit them with hard objects. Do not use any bent or cracked piping, tubes or hoses. They
may burst during use.
Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.
Use only factory approved hoses when replacing them.
SAFETY RULES TO FOLLOW WHEN ADDING FUEL OR OIL

Fuel and oils, can be ignited by a flame. Always observe the following:
• No smoking or open flames during fueling operations.

• Wipe up any spilled fuel, oil, antifreeze or window washer fluid immediately.
• Tighten all fuel, oil, antifreeze and window washer fluid caps securely.
• Use well ventilated areas for adding or storing fuel, oil, antifreeze and window washer fluid.
1-28 WA900-3LC
SAFETY
PRECAUTIONS WHEN HANDLING HIGH PRESSURE SYSTEMS
Keep in mind the work equipment circuits are always under high pressure.
• Do not add oil, drain oil or carry out maintenance or inspection before completely releasing the internal pressure on all
systems.
• Always inspect the condition of your hydraulic hoses and lines before operating your machine. Frayed, bulging, weather
damaged, cracked or chafed hoses or lines could pose a hazard when under pressure
• If oil is leaking under high pressure from small holes in lines or hoses, the oil mist can be flammable, enter your skin or
eyes. Always wear safety glasses and thick gloves use a piece of cardboard or a sheet of wood to check for oil leakage.
Keep all open flames away from any oil mist.
• If you are hit by a jet of high pressure oil, seek medical attention immediately.
CARRYING OUT MAINTENANCE AT HIGH TEMPERATURES OR HIGH PRESSURES

Immediately after stopping operations, the engine cooling system and oil are at all high
temperatures and under high pressure. Never remove the radiator or cooling system cap
when hot. Never drain or change the filters, this action may result in burns or other
injures. Wait for the temperature to go down, before carrying out the inspection and
maintenance in accordance with the procedures given in this manual.
Cooling and lubricating oil level: See “WHEN REQUIRED” on page 3-24.
Cooling and oil levels: See “CHECKS BEFORE OPERATING THE MACHINE” on
page 2-69.
Change oil, replace filters: See “CHECKS BEFORE OPERATING THE MACHINE” on
page 2-69.
MAINTENANCE OF AIR CONDITIONER

Due to EPA regulations, only trained and licensed personnel are allowed to service or maintain air conditioning systems.
WA900-3LC 1-29
SAFETY
FINAL CHECKS AFTER INSPECTION AND MAINTENANCE
Failure to fully carry out inspection and maintenance or failure to check the function of various equipment or systems may
cause unexpected problems which may lead to personal injury or damage, always ask yourself the following questions:
With the engine is stopped.

• Have all the inspection and maintenance locations been checked?
• Have all the inspection and maintenance items been carried out correctly?
• Have I left any tools or parts inside the machine? This could be dangerous if they get caught in the lever linkage.
• Has any coolant and oil leakage been checked or repaired? Have all bolts been tightened?
Checks when the engine is running.

• Does the equipment or systems work normally?
• Is there any oil leakage when the engine RPM is raised and a load is applied to the hydraulic system?
DISPOSAL OF WASTE MATERIALS

It is against the law to dump waste oils or coolant in a sewer system, rivers, on the
ground, etc.
Always put drain oil or coolant from your machine in the proper containers for recycling
purposes. Never drain them directly on the ground.
Obey all laws and regulations regarding disposal of harmful objects such as oil, fuel,
coolant, solvent, filters, batteries and others.
Consult your local recycling center for assistance or information regarding disposal of
this material.
1-30 WA900-3LC
SAFETY
TIRES
TIRE MAINTENANCE
Disassembly, repair and assembly of tires requires special equipment and skill, ask your tire repair shop to perform the repairs.
HANDLING TIRES
If tires are not used under the specified conditions, they may overheat and burst or they may be cut by sharp stones on rough
road surfaces. This may lead to serious injury or damage.
To maintain safety, always the proper procedures:
• Inflate the tires to the specified pressure. Abnormal heat is generated particularly when the inflation pressure is too low.
See “HANDLING THE TIRES” on page 2-104.
• Avoid overloading. See “SELECTING BUCKETS AND TIRES” on page 5-3.
• Use only approved tires.
• The values given in this manual for the tire inflation pressure and permissible speeds are general values. The actual values
may differ depending on the type of tire and the condition under which they are used. For details, please contact your
distributor or tire maker.
• When inflating the tires, use an air chuck with a lock on device. When inflating tires, parts of the wheel may fly off. Never
stand in front of the tire. If possible inflate tires in a tire safety cage.
• Do not adjust the tire inflation pressure immediately after traveling at high speed or after carrying out work under high
loads.
• If the tire is hot when installed on the wheel, flammable gas is produced. If this catches fire, the tire may explode and
cause serious injury or damage. Unlike when a tire is punctured and bursts, if a tire explodes, it produces a highly
destructive force, the following operations are strictly prohibited when the tire is installed to the wheel.
Welding on the rim.
Performing cutting operations or welding near the wheel or tire can be dangerous.
If you do not understand the proper procedure for carrying out maintenance or replacement of the wheel or tire, serious
injury or damage may result. When carrying out such maintenance, consult your distributor or tire maker.
WA900-3LC 1-31
SAFETY
STORAGE OF TIRES AFTER REMOVAL
As a basic rule, store all tires in a warehouse where unauthorized personnel cannot enter. If the tires are stored outside, always
erect a fence around the tires and put up no entry and other warning signs that even young children can understand.
Stand the tire on level ground and barricade it securely with wooden blocks so the tire cannot roll or fall over.
If the tire should fall over, get out of the way quickly. The tires for mining equipment are extremely heavy, trying to hold the
tire may lead to serious injury.
1-32 WA900-3LC
SAFETY
SAFETY LABLE LOCATONS
Always keep these labels clean. If they are lost or damaged, replace them with a new label. There are other labels in addition to
the safety labels listed as follows, so handle them in the same way. Safety labels may be available in languages other than
English. To find out what labels are available, contact your distributor.
WA900-3LC 1-33
SAFETY
1-34 WA900-3LC
SAFETY
SAFETY LABLES
Your machine should be equipped with the following labels, be sure they are there and in good condition.
• Request (part number 427-93-A1141) for safety labels 1 to 3
1. Precautions before starting the machine
Improper operation and maintenance can cause serious injury or

death.
Read manual and labels before operation and maintenance. Follow

instructions and warnings in manual and in labels on machine.
Keep manual in machine cab near operator. Contact KOMATSU

distributor for a replacement manual.
2. Precautions for safety lever
To avoid hitting unlocked operation levers, lower equipment to

ground and move SAFETY LOCK LEVER to LOCK position
before standing up from operators seat.
Sudden and unwanted machine movement can cause serious injury

or death.
WA900-3LC 1-35
SAFETY
3. Precautions when in reverse.
To prevent SEVERE INJURY or DEATH, do the following before

moving machine or its attachments.
• Honk horn to alert people nearby.
• Be sure no one is on or nearby machine.
• Use spotter if view is obstructed.
Follow above even if machine equipped with back up alarm and
mirrors.
• Request (part number 426-93-21570) for safety labels 4 to 6
4. Do not enter.
Crush hazard. Can cause sever injury or death. When machine is

being operated, never place yourself in articulating area of
machine.
1-36 WA900-3LC
SAFETY
5. Precautions for safety bar.
If safety bar is unlocked, machine can jack knife unexpectedly

when it is being transported or hoisted.
Jack knifing can cause serious injury or death to bystanders.
• Always lock safety bar when machine is being transported or

hoisted.
• If necessary, lock safety bar during servicing or maintenance.
6. Precautions with hot coolant.
Hot water hazard.
To prevent hot water from spurting out:

• Turn engine off
• Allow oil to cool
• Slowly loosen cap to relieve pressure before removing
WA900-3LC 1-37
SAFETY
• Request (part number 421-93-21311) for safety labels 7 and 8
7. Precautions with hot oil
Hot oil hazard.
To prevent hot oil from spurting out:

• Turn engine off
• Allow oil to cool
• Slowly loosen cap to relive pressure before removing
8. Precautions with battery cables.
Improper use of booster cables and battery cables can cause

an explosion resulting in serious injury or death.
Follow instructions in manual when using booster cables and

battery cables.
• Part numbers listed on decal surface 9 to 17
9. No tools in the battery box (Affixed to the machine by

battery manufacturer)
Never put any object in the battery box.
There is the danger that it may contact a terminal and cause a

short circuit.
1-38 WA900-3LC
SAFETY
10. High pressure warning.
Explosion hazard.
• Keep away from flame
• Do now weld or drill
11. Precautions for operation or maintenance.
1. When starting the machine or when

traveling observe the following:
(1) When with backhoe withdraw outrigger
perfectly
(2) Check each gauge and pilot lamp
(3) Release parking brake and start machine
(4) Use parking brake only after
machine completely stopped except in
emergencies
(5) When descending a slope travel at a
speed
sufficient to ascending the slope, and do
not set the gearshift lever in neutral.
2. When carrying out maintenance:
(1) Park the machine on level ground
(2) Lower work equipment on the ground
and lock the lever
(3) Do not go under the machine when it
raised by the work equipment
12. Precautions with hot torque converter oil.
1. Under normal operating conditions, indicator

lights should remain in the green area.
2. If the indicator light moves into the red range on
working or prolonged transport driving, reduce load
or decrease machine speed by down shifting or
reducing engine speed.
3. If the alarm buzzer sounds and the warning lamp
flashes due to further operation, stop the machine
and run the engine at mid range speed with no load
until the indicator light goes into the green range.
If the indicator light remains in the red range,
determine the cause of the problem.
WA900-3LC 1-39
SAFETY
13. Do not go under work equipment.
14. Keep cover closed when engine is running.
15. Warning to leave the ROPS as-is.
1-40 WA900-3LC
SAFETY
16. Joystick steering precautions
(if equipped).
17. Keep away from machine.
WA900-3LC 1-41
SAFETY
MEMORANDUM
1-42 WA900-3LC
2OPERATION
WA900-3LC 2-1
OPERATION
GENERAL VIEW
PROFILE OF MACHINE
Directions indicated in this section refer to the views in the profile shown above.
All views are viewed from the operating position in the operator’s seat on the machine.
2-2 WA900-3LC
OPERATION
VIEW OF CONTROLS AND GAUGES
OPERATORS COMPARTMENT
1. Steering wheel 17. Safety lock lever

2. Main monitor 18. Accelerator pedal
3. Lamp switch/turn signal lever 19. Brake pedal
4. Parking brake switch 20. Steering column tilt lever
5. Starting switch 21. Brake pedal
6. Radio 22. Step light switch
7. Cigarette lighter 23. Joystick steering lever
8. Multiple use top switch 24. ECM (engine) diagnostic center
9. Multiple use side switch 25. Front wiper switch
10. Boom control lever 26. Rear wiper switch
11. Bucket control lever 27. Air conditioner panel
12. Hand rest 28. Speed control lever stopper
13. Joystick steering switch 29. Speed control lever
14. Right power window switch 30. Directional lever
15. Left power window switch 31. Hazard lamp switch
16. Maintenance monitor 32. Horn switch
WA900-3LC 2-3
OPERATION
MAIN MONITOR
33. Transmission manual selection pilot 34. Parking brake pilot lamp 35. Centralized warning lamp
lamp and switch
36. Speedometer 37. Transmission shift indicator 38. Engine low idle switch
39. Auto greasing switch 40. Ground driven steering monitor 41. Turn signal pilot lamp
42. Centralized checking lamp 43. Engine preheating pilot lamp 44. Front working lamp pilot lamp
45. Rear working lamp pilot lamp 46. Transmission cut off pilot lamp
MAINTENANCE MONITOR
47. Engine oil pressure lamp 48. Engine oil level lamp 49. Engine coolant level lamp
50. Fuel gauge 51. Engine coolant temperature gauge 52. Converter temperature gauge
53. Service meter 54. Air cleaner pilot lamp 55. Charge monitor
56. Transmission filter pilot lamp 57. Brake oil pressure lamp
2-4 WA900-3LC
OPERATION
OVERVIEW OF COMPONENT
The following is an explanation of the controls needed when operating this machine.
To carry out operations correctly and safely, it is important to understand the systems, equipment and displays on your
machine.
MACHINE MONITOR
The machine monitor system consists of the main monitor, in front of the operator’s seat and the maintenance monitor, on the
right side of the operator’s seat.
The monitor system can be divided into the alarm display portions (B, E), the meter display portions (A, C, D,) and an optional
display portion (F).
ALERT DISPLAY INDICATORS (B, E)

These consist of the centralized check lamp (CHECK), warning lamps (CAUTION) and (engine coolant level, engine oil
level, brake oil pressure, engine oil pressure, battery charge and air cleaner clogging) warning lamps.
GUAGE DISPLAY SYSTEM (A, C, D)

These consists of a variety of gauges, (speedometer, fuel gauge, engine coolant temperature gauge, torque converter oil
temperature gauge, service meter, transmission shift indicator) and additional lamps (turn signal indicator, preheating, front
working lamp, rear working lamp, transmission cut off, parking brake).
OPTION DISPLAY SYSTEM (F)

This consists of the monitor lamps and the switch for the auto greasing system. For details, see “AUTO GREASING SYS-
TEM” on page 5-4.
WA900-3LC 2-5
OPERATION
TESTING MACHINE MONITOR SYSTEM
When the ignition switch is turned to the ON position before starting
the engine, all monitor lamps and gauges will operate for approximately
3 seconds and an alarm buzzer will sound for about 1 second.
When this happens, number 88 (A) is displayed on the speedometer

and number 8 (B) is displayed on the transmission shift indicator.
There will be two beeps to indicate the monitor check has been
completed.
If the monitor lamps do not light, there is probably a failure or

disconnection, contact your distributor for inspection before operating machine.
When the ignition switch is turned to the ON position, and the directional lever is not in the neutral position, the central
warning lamp (CAUTION) will flash, the alarm buzzer will sound intermittently.
If this situation happens, move the lever to the neutral position and the lamps will go out and the buzzer will stop.
A monitor check cannot be carried out for 30 seconds after the engine has been shut down.
2-6 WA900-3LC
OPERATION
WARNING DISPLAYS
(1) Check Lamp (7) Battery Charge Caution Lamp
(2) Caution Lamp (8) Air Cleaner Restriction Lamp
(3) Engine Coolant Level Caution Lamp (9) Transmission Oil Filter Lamp
(4) Engine Oil Level Caution Lamp (10) Ground Driven Steering Lamp
(5) Brake Oil Pressure Caution Lamp (11) ECM Diagnostic Warning Lamps
(6) Engine Oil Pressure Caution Lamp
CENTRAL LAMPS
If this monitor flashes, perform an inspection and on the

appropriate location immediately.
CHECK LAMP
If any abnormality is found before starting the engine (engine oil
level, engine coolant level etc.), the monitor lamp for the abnormal
location will flash as well as the central (CHECK) lamp. Check the
location of the problem before starting. When performing checks, do not rely on just the monitor. Always carry out the
specified maintenance inspection.
If the engine oil level is low before starting the engine, the oil level will change after the engine has been started and the central
CHECK lamp and monitor lamp will stop flashing. The oil level will still be low, always check your oil level before starting
your machine.
A low engine coolant level will also cause the central (CHECK) lamp to flash and the alarm buzzer to sound intermittently
after starting the engine.
WA900-3LC 2-7
OPERATION
If any abnormality in the charging system exists when the engine is running, the battery charge lamp and the central (CHECK)
lamp will flash at the same time. If the lamps flash, check the charging circuit.
CAUTION LAMP
If this monitor lamp flashes, stop the engine immediately or

run the engine at a low idle.
If there is a (CAUTION) indication when the engine is running (engine

coolant temperature, torque converter oil temperature, engine coolant
level, brake oil pressure, engine oil pressure), the alarm buzzer will
sound intermittently and the monitor lamp for the location of the
abnormality will flash along with the central (CAUTION) lamp.
If the fuel gauges is in the red range when the engine is running, the low
fuel indication and the central (CAUTION) lamp will flash. If they flash,
check the fuel level immediately.
ENGINE COOLANT LEVEL CAUTION LAMP

This lamp warns the operator of a low coolant level situation in the radiator.
When carrying out checks before starting (main switch on, engine stopped):
If the coolant level in the radiator is low, the warning lamp and central
(CAUTION) lamp will flash.
If the monitor lamps flash, check the coolant level in the radiator and sub
tank immediately. Add coolant, if needed.
When operating (engine running):
If all is normal, the (CAUTION) lamp should remain off. If the coolant level is
too low, the warning lamp and central (CAUTION) lamp will flash, and the
alarm buzzer will sound intermittently.
If these monitor lamps flash, stop the engine and check the coolant level in the
radiator and sub tank immediately. Add coolant, if needed. Stop the machine on
level ground before performing this check.
2-8 WA900-3LC
OPERATION
ENGINE OIL LEVEL CAUTION LAMP
This lamp warns the operator when the oil level in the engine oil pan has dropped.
When carrying out checks before starting:
If the oil level in the engine oil is low, the oil level warning lamp and central
(CHECK) lamp will flash.
If the monitor lamps flash, check the oil level in the engine and add oil if needed.
When operating:
Even if the engine oil level lamp is flashing during initial checks before starting,
it will go out when the engine is running. The oil level will still be low,
always check your oil level before starting your machine.
BRAKE OIL PRESSURE CAUTION LAMP

This lamp warns the operator the brake oil pressure has dropped.
When carrying out checks before starting:
When the engine is stopped, the brake oil pressure circuit is not actuated, the
warning lamp and central (CHECK) lamp will be off.
When operating:
If the brake oil pressure drops, the warning and central (CAUTION) lamp will
flash and the alarm buzzer will sound intermittently. If these monitor lamps
flash, stop the engine immediately and check the brake oil pressure circuit.
Remark
The monitor lamp may flash and go out after about 10 seconds once
the engine is started, this is because of the pressure stored in the brake
accumulator. No malfunction is indicated
ENGINE OIL PRESSURE CAUTION LAMP

This warns the operator if the engine lubricating oil pressure has dropped.
If it flashes, stop the engine and check engine oil level immediately.
Before starting:
Lights will light up
Engine running:
When the engine is running, and lubrication pressure is up the lamps will be out.
If the oil pressure drops, the oil pressure warning lamp and central
(CAUTION) lamp will flash, and the buzzer will sound intermittently.
WA900-3LC 2-9
OPERATION
BATTERY CHARGE CAUTION LAMP
This lamp warns the operator of a malfunction in the charging system when the engine
is running.
Before starting:
Lights will light up
With engine running:

When the engine is running, the alternator generates electricity causing the lamp
to go out. If any abnormality occurs in the charging system, the charge
warning lamp and central (CHECK) lamp will flash. If they flash, check the
engine charging system immediately.
AIR CLEANER RESTRICTION LAMP

When the engine is running, this lamp warns the operator of an the air cleaner
element restriction.
Before starting:
Light is off.
When operating:
If the air cleaner element should become clogged, the air cleaner warning lamp
and central (CHECK) lamp will flash. If they flash, clean or replace the element
immediately.
TRANSMISSION OIL FILTER LAMP

This warns the operator the transmission oil filter is restricted.
If this lamp flashes, stop the machine and replace the filter element immediately.
2-10 WA900-3LC
OPERATION
GROUND DRIVEN STEERING LAMP
This indicates the main pump is operating normally when the machine is
traveling.
If the engine stops when the machine is traveling or if there is any

abnormality in the pump circuit, the monitor flashes to indicate the ground
driven steering system has been actuated. If the monitor flashes, stop the
engine immediately.
ECM DIAGNOSTIC WARNING LAMPS

R - Red lamp: This lamp will light in the event of a major engine
failure that will cause severe engine damage.
Y - Yellow lamp: This lamp will light in the event of a less severe
engine failure where engine damage may occur
if the problem is not corrected immediately.
O - Orange lamp: This lamp will light when the operating conditions
are out of the normal range (e.g. engine over heat).
For more details, see “ENGINE CONTROL MODULE (ECM)” on

page 2-32.
WA900-3LC 2-11
OPERATION
METER DISPLAY PORTION
(1) Parking Brake Lamp (8) Fuel Gauge
(2) Preheating and after Heating Lamp (9) Engine Coolant Temperature Gauge
(3) Front Work Lamp Indicator (10) Torque Converter Temperature Gauge
(4) Rear Work Lamp Indicator (11) Service Hour Meter
(5) Transmission Cut Off Indicator Lamp (12) Speedometer
(6) Turn Signal Indicator Lamp (13) Transmission Shift Indicator
(7) Transmission Shift Selection Lamp
SYSTEM INDICATOR LAMPS AND GUAGES

When the ignition switch is on, the systems indicator lamps light up
for each function listed.
PARKING BRAKE LAMP

This lamp lights up when the parking brake is applied.
Do not operate machine with parking brake applied, severe damage

may occur.
2-12 WA900-3LC
OPERATION
PREHEATING AND AFTER HEATING LAMP
When ignition, switch is on the lamp will inform you a preheating
process has been started.
When starting or operating your machine in cold weather, the lamp

will flash until the coolant temperature reaches 20°C (68°F), informing
you the after heating has been started.
FRONT WORK LAMP INDICATOR

This lamp lights up when the front working lights are on.
REAR WORK LAMP INDICATOR

This lamp lights up when the rear working lights are on.
TRANSMISSION CUT OFF INDICATOR LAMP

This lamp lights up when the transmission cut-off switch is on.
If the monitor lamp is on and the left brake pedal is depressed, the
transmission will be returned to neutral.
WA900-3LC 2-13
OPERATION
TURN SIGNAL INDICATOR LAMP
When the turn signal is used the turn indicator lamp flashes.
TRANSMISSION SHIFT SELECTION LAMP

This lamp illuminates when the transmission is set in the manual mode.
While the monitor lamp is illuminated, it is possible to shift gear with

the gear shift lever.
FUEL GAUGE
This gauge indicates the amount of fuel in the tank.
E - Indicates an empty tank

F - Is a full tank
The display should indicate in the green range during normal operation.
If it enters the red range, the fuel gauge (low fuel) warning lamp and
central (CAUTION) lamp will flash.
When in the red range, it means that there is less than 200 liter (53 gal) of
fuel left, check or add fuel.
ENGINE COOLANT TEMPERATURE GAUGE

This gauge indicates the temperature of the engine coolant.
If the temperature is normal during operation, the gauge will indicate in

the green range.
If the gauge display shows in the red range, during operation, stop
the machine and run the engine with no load at mid range speed until
the green range returns. If the lamps light up to the 1st red level, the
engine coolant temperature gauge lamp and central (CAUTION) lamp
will flash; when the lamps light up to the 2nd red level, the alarm
buzzer will also sound intermittently.
2-14 WA900-3LC
OPERATION
TORQUE CONVERTER TEMPERATURE GAUGE
This gauge indicates the temperature of the torque converter oil.
If the temperature is normal during operation, the gauge will indicate in

the green range.
If the gauge display shows in the red range stop the machine and run
the engine with no load at mid range speed until the green range returns.
If the lamps light up to the 1st red level, the torque converter oil
temperature gauge lamp and central (CAUTION) lamp will flash;
when the lamps lights up to the 2nd red level, the alarm buzzer will
also sound intermittently.
SERVICE HOUR METER

This meter shows the total operation hours on the machine.
The service hour meter advances while the engine is running, even if
the machine is not traveling.
While the engine is running, the green pilot lamp on the service
meter flashes to show the service meter is advancing.
The service meter progresses by 1hr. when the engine is operated for
one hour, regardless of the engine speed.
SPEEDOMETER
This meter indicates the ground travel speed of the machine.
WA900-3LC 2-15
OPERATION
TRANSMISSION SHIFT INDICATOR
Joystick Steering Not Engaged
This indicates the present speed range of the transmission.
When the directional lever is in the neutral position, (N) is displayed on

the indicator.
When the directional lever is in the F (forward) or R (reverse) position,

that positions speed is displayed in a a numerical form.
Joystick Steering Engaged
This indicates the transmission speed range. When the N button or the
FNR buttons on the head of the joystick lever are pressed, the indicator
displays N.
When the F or R button or the FNR buttons on the head of the

joystick lever are pressed, F or R is displayed at the bottom of the
speedometer and the shift indicator displays the transmission speed
range.
2-16 WA900-3LC
OPERATION
SWITCHES
(1) Ignition Switch (13) Parking Brake Switch
(2) Transmission Cut Off Switch (14) Cigarette Lighter
(3) Front Work Lamps (15) Joystick Steering ON/OFF Switch
(4) Rear Work Lamps (16) Joystick Steering Lever Switches
(5) Transmission Manual Selection Switch (17) Step Light Switch
(6) Lamp Switch and Turn Signal Lever (18) Cab Lamp Switch
(7) Horn Button (19) Power Window Switches (Right and Left)
(8) Hazard Lamp Switch (20) Multiple Use Top Switch
(9) Front Wiper Switch (21) Multiple Use Side Switch
(10) Rear Wiper Switch (22) Engine Low Idle Selector Switch
(11) ECM ON/OFF Switch (23) Auto Grease
(12) ECM Select Switch
WA900-3LC 2-17
OPERATION
IGNITION SWITCH
This switch is used to start or stop the engine.
OFF
The key can be inserted and removed in this position. When the key is turned to
this position, the electric circuit is turned off and the engine will be stopped.
ON
Electric current flows in the charging circuit, lamp and accessory circuits.
Keep key in the ON position to keep the engine running.
START
This is the engine start position. Turn the key to this position to start the engine cranking.
Immediately after engine starts, release the key which will automatically return to the ON position.
TRANSMISSION CUT OFF SWITCH
If the machine has to be started on a slope, set the transmission cut off switch to the OFF position while
depressing the left brake pedal. Then, depress the accelerator pedal while releasing the left brake pedal
to start the machine off slowly.
Press the push button switch (1) to turn ON or OFF. When the switch
is pressed, the lamp (2) will light up if the switch is pressed again, the pilot
lamp will go out and the transmission cut off will be turned off.
Normally operate with this switch in the ON position.
OFF - Acts as a normal brake, like right brake pedal.
ON - Acts as a normal brake, but also switches the transmission

to NEUTRAL.
If the switch is ON, the transmission cut-off pilot lamp lights up.
Remark
General loading work can be carried out more smoothly if the transmission cut off function is not used.
2-18 WA900-3LC
OPERATION
FRONT WORK LAMPS
Always turn the working lamp off before traveling on public

roads.
When turning on the front working lamps, turn the lamp switch (Item
6 on the steering column) to the ON position for the side clearance lamp or
the ON position for the head lamp, then operate the switch (1). When the
switch is pressed, the pilot lamp (2) will light up and come on; if the switch
is pressed again, the pilot lamp will go out and the working lamp
will be turned off. The working lamp will not light up if the lamp switch
is not in the ON position for the side clearance lamps or the head lamps.
REAR WORK LAMPS
Always turn these lamps off before traveling on public roads.
When using rear working lamps, turn the switch (Item 6 on the
steering column) to the ON position for the side clearance lamp or the
head lamp, then actuate switch (1). When the switch is pressed, the
pilot lamp (2) will light up, if the switch is pressed again, the pilot
lamp will go out and the working lamp will be turned OFF. The
working lamps will not light up if the lamp switch is not in the ON
position for the side clearance lamps or head lamps.
TRANSMISSION MANUAL SELECTION SWITCH

Press the push button (1) to turn system ON or OFF. If the switch
is pressed once, the pilot lamp (2) lights up and the system is switched
on. If it is pressed again, the pilot lamp goes out and the system is
switched off.
Normally operate with this switch in the OFF position.
OFF - Automatic gear shifting (pilot lamp off)
ON - Manual gear shifting (pilot lamp on)
If the switch is turned ON, the transmission manual selection pilot
Remark
For details of manual gear shifting and automatic gear shifting, see CONTROL LEVERS, PEDALS on
page 2-27★
WA900-3LC 2-19
OPERATION
LAMP SWITCH AND TURN SIGNAL LEVER
Lamp Switch
This is used to control the head lamps, side clearance lamps, tail lamps
and instrument panel lighting.
A: OFF
B: Side clearance lamp, tail lamps and gauge

lighting.
C: Head lamps light up in addition to the lamps at

position.
Remark
The lamp switch can be operated regardless of the lever position.
Turn Signal Lever
This lever operates the turn signal lamps.
A: LEFT TURN: Push the lever forward.

B: RIGHT TURN: Pull the lever back.
Remark
When this lever is operated, the turn signal pilot lamp will
also flash. When the steering wheel is turned to the neutral
position, the turn signal lever will return automatically to
OFF position. If not, return the lever to OFF position manually.
HORN BUTTON
This button is in the center of the steering wheel when pressed, the horn will sound.
2-20 WA900-3LC
OPERATION
HAZARD LAMP SWITCH
Use the hazard lamps only in emergencies. Using the hazard

lamps when traveling may cause problems for other
machines.
This switch is used in emergencies, such as when the machine breaks

down;
ON: All turn signal lamps will flash.
Remark
When switch is turned to the ON position, the turn directional indicator lamps and turn indicator pilot lamp (A)
flashes.
FRONT WIPER SWITCH

Turn switch (A) to operate the front wiper.
Switch Position Window Display (Z) Operation
1 OFF OFF
2 INT Intermittent
3 Low speed
4 High speed
If button (B) is kept pressed, washer fluid will be sprayed onto the front glass.
REAR WIPER SWITCH

Turn the lever (C) to operate the rear wiper.
Switch Position Display Operation
1 Washer fluid sprayed
2 OFF OFF
3 Wiper actuated
4 Washer fluid & wiper
WA900-3LC 2-21
OPERATION
ECM ON/OFF SWITCH
These ON/OFF switches are used to change the ECM to a diagnostic
mode. If an active fault is present, the diagnostic lights will flash to give
you the three digit fault code.
For further details, see “ENGINE CONTROL MODULE (ECM)” on

page 2-32.
ECM SELECT SWITCH

In the event of multiple faults, the select switches give the operator or tech-
nician the capability to change from one fault code to the next forward or
backward.
For further details, see “ENGINE CONTROL MODULE (ECM)” on page 2-32.
PARKING BRAKE SWITCH
Always apply the parking brake when leaving your machine

or parking it. Even if the parking brake switch is turned ON,
there is a danger until the parking brake lamp lights up. Keep
the brake pedal depressed.
This switch operates the parking brake.
A: ON: The parking brake is applied and the parking brake lamp lights up.
B: OFF: The parking brake is released.
If the directional lever is placed in F or R with the parking brake applied, the warning lamp will flash and the alarm buzzer will
sound. When the ignition switch is turned to the OFF position, the parking brake is automatically applied. Before starting the
engine, turn the parking brake switch to the ON position, then turn it to the OFF position.
Remark
The machine will not start when the directional lever is operated with the parking brake applied.
Never use the parking brake switch to apply the brakes when traveling, except in an emergency.
Apply the parking brake only after stopping the machine.
If the parking brake has been used as an emergency brake when traveling at high speeds, contact your
distributor to have the parking brake checked for damage.
2-22 WA900-3LC
OPERATION
CIGARETTE LIGHTER
This item is used to light cigarettes.
To use, push the lighter button in. After a few seconds it will spring back.
Remove the lighter and light your cigarette.
JOYSTICK STEERING ON/OFF SWITCH

This switch is used to control the joystick steering.
For further details, see “JOYSTICK STEERING” on page 2-48.
JOYSTICK STEERING LEVER SWITCHES

Select the forward or reverse direction or the neutral position with the FNR button on joystick head.
N: Neutral: Sets the machine in neutral when either of these buttons are pushed.
F: Forward: Sets the machine in forward when this button is pushed.
R: Reverse: Sets the machine in reverse when this button is pushed.
WA900-3LC 2-23
OPERATION
STEP LIGHT SWITCH
This is used to illuminate the left rear step and ladder.
If the operator presses this switch when getting off the machine, the lamp
lights up for about a minute then goes off automatically.
CAB LAMP SWITCH

This switch turns on the cab interior lamp.
A: OFF
B: Lights up when the cab door is opened
C: Lights up manually
POWER WINDOW SWITCHES (RIGHT and LEFT)
When closing the window glass, be careful not to catch anyone’s hand or face in the window glass, as this
can cause serious injury. Do not keep operating the power window switch after the window glass is fully
opened or closed. This operation will cause trouble with the power window unit.
These switches can be used while the ignition switch is in the ON

position. Press (A), and the side glass will lower. Press (B), and the side
glass will rise.
When the glass reaches the top or bottom, release the switch. The
inner switch operates the left side glass and the outer switch operates
the right side glass.
2-24 WA900-3LC
OPERATION
MULTIPLE USE TOP SWITCH
With Joystick Steering Disengaged - Kick Down Switch
When the speed control lever is in second gear and the switch on the
top of the boom control lever is pressed, the transmission will down shift to
first gear.
This switch is used to increase the drawbar pull in digging operations.
Remark
To cancel the kick down switch, move the directional lever
to the REVERSE or NEUTRAL position or move the
speed control lever to any position, except second gear.
It is also possible to cancel the kick down switch by operating
the parking brake switch or by turning the ignition switch OFF.
With Joystick Steering Engaged - Shift Down Switch
When the switch on the top of the knob, boom control lever is pressed, the transmission will down shift to the next
lower gear.
MULTIPLE USE SIDE SWITCH

With Joystick Steering Disengaged - Hold Switch
To hold the gear shift range when using automatic gear shifting, press the
switch on the side of the boom control lever knob. The speed range dis-
played on the transmission indicator main monitor will display HOLD.
If the switch is pressed again, the HOLD function is canceled and the dis-
play goes out. Use this function to set to the desired speed range when trav-
eling uphill or downhill or when carrying out grading.
For further details, see “AUTO SHIFT SYSTEM” on page 2-56.
Remark
If the gear shifting operation is carried out with the gear shift lever, it is
possible to shift down or shift up from a fixed speed range.
With JoyStick Steering Engaged - Shift Up Switch
When the switch on the side of the knob, boom control lever is pressed, the transmission will shift up
to the next higher gear.
WA900-3LC 2-25
OPERATION
ENGINE LOW IDLE SELECTOR SWITCH
The engine low idle speed can be switched between two levels with
this switch. Press the button to turn it on or off. If the switch is
pressed once, the pilot lamp lights up and the system is switched ON.
If it pressed again, the pilot lamp goes out and the system is switched OFF.
OFF:This returns the engine to low idle speed to approximately 650

rpm. This is used for normal operations at low idle, such as
waiting for trucks.
ON:This increases engine speed to approximately 850 rpm.

This is used for busy work sites where it is necessary to
reduce cycle times.
AUTO GREASE
This is used for auto grease system.
For further details, see “AUTO GREASING SYSTEM” on page 5-4.
2-26 WA900-3LC
OPERATION
CONTROL LEVERS AND PEDALS
(1) Speed Control Lever (6) Boom Control Lever
(2) Directional Lever (7) Brake Pedals
(3) Speed Control lever Lock (8) Accelerator Pedal
(4) Safety Lock Lever (9) Joystick Steering Lever
(5) Bucket Control Lever
WA900-3LC 2-27
OPERATION
SPEED CONTROL LEVER
Use this lever to control the travel speed of the machine. This machine
has a 3-Forward and 3-Reverse speed transmission. Place the speed
control lever in the position required to obtain the desired speed range.
When the speed control lever lock is being used, you will not be able
to shift into 3rd. Disengage the speed control lever lock before trying
to shift gears.
A: 1st speed is used for heavy work
B: 2nd speed is used for general working
C: 3rd is used for traveling.
Remark
The length of the lever can be adjusted to 3 stages (position D, E or F). To adjust
the length, remove the screw at the bottom of the lever and slide the knob to
the desired position. Install and tighten the screw again. The lever is installed at
position E when the machine is shipped from the factory.
DIRECTIONAL LEVER
This lever is used to change the direction of travel.
The engine cannot be started if the directional lever is not in N, neutral.
A: Forward direction
B: Neutral
C: Reverse
Remark
The length of the lever can also be adjusted to 3 stages (position D, E or F).
To adjust the length, remove the screw at the bottom of the lever and slide the
knob to the desired position. Install and tighten the screw again. The lever is
installed at position E when the machine is shipped from the factory.
2-28 WA900-3LC
OPERATION
SPEED CONTROL LEVER LOCK
This lock prevents the speed control lever from entering the 3rd gear
range when working.
A: Locked
B: Unlocked
SAFETY LOCK LEVER
When leaving the operators compartment, set the safety lock

lever in the LOCK position. If the control levers are not
locked and touched by mistake, this may lead to a serious
accident. If the safety lock lever is not placed securely in the
LOCK position, the control levers may not be properly
locked. Check the situation as shown in the diagram. When
parking the machine or carrying out maintenance, always
lower the bucket to the ground and apply the lock.
This lever is used to lock the work equipment levers. Push the lever down to apply the lock.
BUCKET CONTROL LEVER

This lever operates the bucket.
A: TILT When the bucket control lever is moved to the

BACK TILT BACK position, the lever will lock if you
pull it all the way back to the lock position. When
the bucket reaches a preset position the lever will
return to the HOLD position and all functions will
stop.
B: HOLD The bucket is kept in the same position.
C: DUMP Move the lever forward past hold and the bucket
will tilt forward.
WA900-3LC 2-29
OPERATION
BOOM CONTROL LEVER
This lever operates the boom.
A: RAISE When the boom control lever is moved to the

RAISE position, the lever will lock if you pull it all
the way back to the lock position. When the boom
reaches a preset position the lever will return to the
HOLD position and all functions will stop.
B: HOLD The boom is kept in the same position.
C: LOWER Move the lever forward past hold and the boom will
lower to the ground
D: FLOAT With the boom lowered to the ground. If you push

the control lever all the way forward the lever will
lock in a free floating non-hydraulic position under
under the weight of the boom and implements.
Remark
Never travel forward when the boom is in the FLOAT position.
The bucket leading edge will dig in, raise the machine up, or
stop the machine suddenly.The FLOAT feature should only be
used when traveling backwards, or backdraging.
BRAKE PEDALS
When traveling downhill, always turn the transmission cut-

off switch in the OFF position. Use the engine as a brake and
always use the right brake pedal. Avoid using the brake ped-
als repeatedly, unless necessary. Do not put your foot on
this pedal, unless necessary. Do not ride the brakes when
traveling.
Right Brake Pedal
If the right brake pedal is depressed, the wheel brakes are applied.
Left Brake Pedal
If the left brake pedal is depressed, the wheel brakes are applied. The left brake pedal will act in the same way as the right
brake pedal. When the transmission cut-off switch is in the ON position, and the left brake pedal is depressed, the brakes
are applied and the transmission will automatically return to a neutral position.
Remark
When the accelerator pedal is used for operating the work equipment, place the transmission cut off switch in
the ON position and use the left brake pedal to slow or stop the machine.
2-30 WA900-3LC
OPERATION
ACCELERATOR PEDAL
This pedal controls the engine speed. The engine speed can be freely
controlled between low idle and full speed.
JOYSTICK STEERING LEVER

Move the joystick steering lever to the left or right to turn the machine.
WA900-3LC 2-31
OPERATION
ENGINE CONTROL MODULE (ECM)
ON/OFF SWITCH
The ON/OFF switch (1) is used to change the ECM to a diagnostic mode. In this mode, if an active fault is present, the
diagnostic lights will flash and give you the three digit fault code. In event of multiple faults, switch (2) gives you the
capability to change from one fault code to the next forward or backward.
ECM DIAGNOSTIC WARNING LIGHTS

The three diagnostic lights (3) located on the left side of the monitor
panel are there to warn of an engine malfunction. The lights are
controlled exclusively by the ECM. In the event of an engine
malfunction, one or more lights will illuminate to alert the operator
of a malfunction with the engine. Each lamp indicates a different
degree of severity.
Their functions are as follows:
Red Lamp --- STOP This lamp will illuminate in the event of a
major engine failure that will cause severe engine damage. When this
lamp is activated, the accelerator pedal will become inactive forcing the operator to stop all operations. The engine will then
run at a constant 1000 rpm allowing the operator to maneuver the machine to a safe location where it can be shut down.
Yellow Lamp --- WARNING This lamp will illuminate in the event of a less severe engine problem where engine damage
may occur if the problem is not corrected immediately. When this lamp is activated, the machine will remain fully functional
allowing the operator to drive it to a suitable location for proper shut down. The operator should not continue working the
machine when the yellow lamp is illuminated.
Orange Lamp --- ENGINE PROTECTION This lamp will illuminate when the operating conditions for the engine are out
of normal operating range, e.g., engine overheat. Since the ECM generates faults independent of the other systems, the Orange
lamp may also be accompanied by a warning light on the monitor panel. When this lamp is illuminated, the machine will
remain fully functional but the cause for the lamp must be identified and corrected as soon as possible.
ENGINE FAULT DIAGNOSTICS

The ECM is programmed to generate three digit fault codes when an engine malfunction occurs. Each of the three diagnostic
lights has a specific set of fault codes that make them illuminate. During normal operation, the operator is informed of the fault
condition by the illuminated fault lamps. The actual three digit code can be obtained by using the two switches located next to
the warning lights. Once the fault code is known, it can be found in the ENGINE TROUBLESHOOTING AND REPAIR
MANUAL.
In order to read the fault codes from the diagnostic lights the engine must be off, key switch must be on, diagnostic switch
must be on. This will cause the orange engine protection lamp to come on.
The red and yellow lamps will be illuminated if there are no faults present. If one or more faults are present the yellow warning
lamp will flash once to show the beginning of the fault code sequence. Then the red stop lamp will flash n times in which n =
the 100's digit of the fault code. After the 100's digit is completed the light will remain off for a ½ second pause and then start
the 10's digit. Again the light will flash n times in which n = the 10's digit. After the 10's digit is completed there will be a 0.5
second pause and the 1's digit will begin. The light will flash n times in which n = the 1's digit. After the fault code is
completed, the yellow warning light will flash to show the beginning of the new fault code. The fault code will be repeated
until the select switch is used to change to the next code or the diagnostic switch is turned off. If there is only one fault code,
the select switch will only cause the current fault code to start over. The diagnostic switch should remain off during normal
operation of the machine. For complete fault code information see ENGINE TROUBLESHOOTING AND REPAIR
MANUAL.
2-32 WA900-3LC
OPERATION
AIR CONDITIONER
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL
(1) Fan Switches (4) Fresh/Recirculating Air selector Switch
(2) Air Conditioner Switch (5) Temperature Control Switch
(3) Vent Selector Switch
(1) Fan Switches
These switches are used to adjust the air flow in four stages. It also acts
as the main switch for the air conditioner. When the switch is pressed,
the indicator lamp above that switch lights up to indicate the air flow.
WA900-3LC 2-33
OPERATION
Air Conditioner Switch
This switch is used to start or stop the cooling or dehumidifying function. When the fan switch
is turned on and the air conditioner switch is pressed, the indicator lamp above the switch lights
up. When the switch is pressed again, the switch is turned off and the indicator lamp goes out.
Vent Selector Switch
This switch is used to select the vents.
The following five vent modes are available: face, face & foot,
foot & defroster or defroster.
When a switch is pressed, the indicator lamp above that switch lights up
to display the vent mode.
Fresh/Recirculating Air Selector Switch
This switch is used to select between recirculating the air inside the cab or taking in outside air.
When the recirculating air position is selected, the indicator lamp above the switch lights up.
When the switch is pressed again, the indicator lamp goes out and outside air is taken in.
2-34 WA900-3LC
OPERATION
Temperature Control Switch
The temperature can be adjusted from low to high temperatures. The

temperature level indicator lamps light up to display the temperature of
the air coming from the vents. The more blue the lamps are, the lower
the temperature. The color of the indicator lamp changes while the
switch is being pressed. When the temperature reaches the desired
level, release the switch to set the temperature. The settings for each
mode are retained in memory even when the ignition switch is turned
off.
However, in the following cases, the settings must be made again.

• When the machine has been out of use for more than 7 days.
• When the battery voltage is low.
• When there has been abnormal interference.
• When the fan switch is turned off, the setting is not kept in memory with only the air conditioner switch.
If the air conditioner is used in the outside air position, the inside of the cab will be pressurized, this will prevent the entry of
dust. The higher the position of the fan switch, the more effective the pressurizing becomes.
WA900-3LC 2-35
OPERATION
EXPLANATION OF OPERATION
Fresh/ Recircu-
Air Condi- Temperature Vent Mode
Use Switch Fan Switch lating Air Con-
tioner Switch Control Selector
trol
Rapid cooling HI ON All blue Recirculating Face

Cooling
Normal cooling HI-LO ON Half blue Fresh Face
Dehumidifying, Heating HI-LO ON Half red Fresh Feet
Rapid heating Hi OFF All red Recirculating Feet

Heating
Normal heating HI-LO OFF Half red Fresh Feet
Defroster HI OFF Half red Fresh Defroster
VEntilation Or Pressurizing Cab HI-LO OFF All blue Fresh Face
When defrosting windows, if the temperature control is set where that all lamps are red, this will improve the defrosting
performance. Set the vent mode selector in the intermediate position to achieve the desired condition. When using the face
vents, it is possible to adjust the direction of air flow or turn it on or off. However, do not set to the face mode with the vents
closed.
COOL BOX
When the air conditioning is being used, this box can be used for
keeping drinks and other things cool.
When heat is being used, it can be used to keep things warm.
When using the box, open the vent grill. When not using the box, close
the grill.
Do not use the cool box for things that leak water or break easily.
Do not use it as a holder for tools or other small objects.
2-36 WA900-3LC
OPERATION
AM/FM STEREO CASSETTE RADIO
EXPLANATION OF COMPONENTS
(1) Power Switch Volume Control Knob (10) Seek Control
(2) Tone Control Knob (11) Loud Control
(3) Bass Control (12) Auto Memory
(4) Treble Control (13) FM AM Band Select
(5) Eject Button (14) Display
(6) Cassette Door (15) Tuner Switch, Manual Tuning
(7) Fast Forward, Rewind, Program Changeover Control (16) Preset Switch
(8) Memory Switch (17) Metal Button (In Tape Mode)
(9) Display Changeover (18) Hour and Minute Correction
WA900-3LC 2-37
OPERATION
Power Switch Volume Control Knob
Turn this knob clockwise until it clicks and the power is turned on. Turn
it further to increase the sound.
Tone Control Knob
Adjust the tone of the sound by turning this knob.
Bass Control
Slide this knob to the right to increase the bass sound and to the left
to decrease the bass.
Treble Control
Slide this knob to the right to enhance high frequency or to the left to
suppress high frequency sound.
2-38 WA900-3LC
OPERATION
Eject Button
Press this button to eject the cassette tape.
Cassette Door
Insert a cassette tape with the exposed magnetic tape side facing right.
Fast Forward, Rewind, Program Changeover Control
To fast forward the tape, press the button matching the direction of
program indication, to rewind, press the other button. To stop fast
forwarding or rewinding, lightly press the button which is not
locked to cancel the operation. The system will then start playing the
tape again. To change, press the fast forward and rewind buttons
simultaneously. The direction of the tape feed will reverse.
Memory Switch
Press this MEMO switch to preset the frequencies of the desired

stations, ME flashes or correct the clock.
WA900-3LC 2-39
OPERATION
Display Changeover
Press this CL.FREQ switch to show the clock display. The frequency
is indicated again automatically about 5 seconds later. The display
always indicates the clock in the tape mode.
Seek Control
When this SEEK button is pressed, the system automatically searches for a
receivable station and automatically stops searching once a station is
picked up.
Loud Control
This button is used to operate the system at a lower volume but

with enhanced bass and treble. LOUD indication appears on the display
at this time.
Auto Memory
When A.MEMO button is pressed, the system tunes itself to

stations receivable in the area in which the machine is currently
located, one after another and memorizes the frequencies in its preset
memory, all automatically.
2-40 WA900-3LC
OPERATION
FM AM Band Select
Pressing this BAND control changes over between FM1, FM2, FM3
and AM bands. The display indicates the receiving band name and
frequency.
Display
This display indicates the clock, radio broadcast and the current
operation mode.
Tuner Switch, Manual Tuning
Pressing the tuner button on the top raises the receiving frequency by
9 kHz in AM and by 0.1 MHz in FM for each press. Pressing the tuner
button on the bottom lowers the receiving frequency similarly.
Pressing either of these buttons continuously shifts the receiving
frequency continuously.
Preset Switch
One station each in the FM1, FM2, FM3 and AM bands, respectively, can
be preset using buttons 1 through 6 shown at right. See “PRESETTING TO
SELECTED STATIONS” on page 2-43.
WA900-3LC 2-41
OPERATION
Metal Button (In Tape Mode)
Pressing the MTL button allows you to use metallic tape. The MTL
indication appears on the display.
Hour and Minute Correction
See “ADJUSTING TIME” on page 2-45.
2-42 WA900-3LC
OPERATION
EXPLINATION OF OPERATION METHODS
PRESETTING TO SELECTED STATIONS
When listening to a preset station, select one of the AM, FM1, FM2 or FM3 bands using band select switch (A), then simply
press the number key corresponding to the preset selected station. The system can memorize 6 stations in AM band and 18
stations in FM bands, FM1: 6 stations, FM2: 6 stations and FM3: 6 stations.
1. If the system is playing a cassette tape, press the eject button to stop the tape.
2. Tune to the desired station:
A. First, select one of the AM, FM1, FM2 and FM3 bands with band select switch (A), then tune to the frequency of the
desired station using the TUNING buttons.
B. Press memory switch (B).
C. While the memory switch (B) is flashing, press the preset switch (C) of the number to be preset. The preset channel
and frequency will be indicated. This concludes presetting.
D. Repeat the above procedure Steps A to C to preset to other desired stations.
Remark
To change a preset station, repeat the above procedures Steps A to C. If the main power supply is interrupted,
such as disconnecting the machine battery, all presetting will be erased. Repeat the presetting procedure.
AUTO MEMORY
When the auto memory switch (A) is pressed, the system tunes itself to
stations receivable in the area where the machine is currently located, one
after another and stores the frequencies in its preset memory, all
automatically.
WA900-3LC 2-43
OPERATION
RECEIVING RADIO BROADCASTS
1 Turn on the ignition key, then turn on power switch (A) on the stereo. Select either AM or FM band with the band select
switch (B). Tune to the desired station using the preset switch or tuner switch (C).
2. Adjust the volume, the balance between left and right speakers and the sound quality to your choice using the respective
buttons. When turning off the radio, turn power switch (A) counterclockwise until it clicks.
Remark
When changing over to radio while listening to a cassette tape, press the EJECT button to stop the tape.
Simply insert a tape to change over to cassette tape mode while listening to the radio.
AUTOMATIC TUNING
Pressing the SEEK switch shifts the receiving frequency in the higher
frequency direction, then stops shifting automatically at a position where
a station is picked up.
MANUAL TUNING
Pressing tuner button (A) raises the receiving frequency by 9 kHz in AM
and by 0.1 MHz in FM for each press. Pressing the tuner button (B) lowers
the receiving frequency similarly. Pressing either of these buttons
continuously shifts the receiving frequency continuously.
2-44 WA900-3LC
OPERATION
SELECTION BETWEEN MODES
When FM stereo broadcasting signals received are too weak for normal
receiving, such as receiving a long distance from the broadcasting station
or in the mountains, the system automatically shifts from stereo to monau-
ral mode to suppress disturbing noise. It automatically returns to stereo
mode when the intensity of the radio wave being received recovers.
ADJUSTING TIME
1 Turn on the ignition key, then turn on the power switch to the
stereo. If the frequency is displayed on the display, change the display
to the clock using the display changeover switch.
2 Pressing and holding the memory switch, press H button to set the
hour and M button to set the minute. About 5 seconds after setting the
time, the display returns to the frequency automatically.
WA900-3LC 2-45
OPERATION
PLAYING A CASSETTE TAPE
1. Turn on the ignition key, then turn on the power switch of the
stereo.
2. Insert your cassette tape in the cassette door with the expose tape
on the right side. The tape will start playing automatically. When the
tape ends in one direction, the system automatically reverses the tape
and plays the other side.
3. To stop the tape, press the eject button to eject it and the system
will automatically change over to radio.
CHANGING TAPE CHANNELS

Lightly press both program changeover buttons (A and B)
simultaneously while the tape is being played.
FAST FORWARDING
To fast forward a tape during playing, fully press either the (A) or (B)
buttons according to the current tape feed direction to lock it.
• When tape feed direction is backwards: Press button (A) to lock it

• When tape feed direction is forward: Press button (B) to lock it
To stop fast forwarding, lightly touch the unlock button. This frees
the locked button and normal playing resumes. If the tape is wound
to the end in the fast forward mode, normal playing resumes.
2-46 WA900-3LC
OPERATION
REWINDING
To rewind the tape, press the button in the opposite direction of the current
tape feed direction to change it.
• When tape feed direction is to the left. Press button (B) to change it
• When tape feed direction into the right. Press button (A) to change it
To stop rewinding, lightly touch the unlock button. This frees the locked
button and normal playing resumes. If the tape is wound to the end in the or
rewind mode, normal playing resumes.
PRECAUTIONS WHEN USING

• Retract the antenna when traveling in places with low overhead clearances.
• For safety reasons, when operating, keep the sound to a level where you can enjoy the sound but still hear the sound from
outside the vehicle.
• If water gets in the speaker case or radio, it may cause a serious damage. Do not let water get on these parts.
• Do not wipe the knobs or buttons or any other parts with solvents such as benzene, thinner etc. Always wipe with a soft
dry cloth, in case of extreme dirt, use a mild cleaner on the cloth.
Handling Cassette Tapes
• Clean the tape head once a month with a tape cleaning product specified for cleaning casette tape drives.
• Do not place a cassette tape on a place where it will be exposed to the direct sunlight, dust or magnetism.
• Do not use a 120 minute tape since it is thin and may be wound in the mechanism.
• If a tape is slack, it may be wound in the mechanism. Eliminate any slack before using.
• If the label on a tape is damaged, it can cause trouble and the cassette may not be ejected.
WA900-3LC 2-47
OPERATION
JOYSTICK STEERING
To ensure you operate the joystick steering system safely and efficiently, it is important to read this section before using.
EXPLANATION OF COMPONENTS
Converts the displacement of the steering lever into a voltage signal to control the steering according
1 Joystick
to the operation of the F N R button.
2 Controller Controls steering according to the voltage signal received from the joystick.
3 Proportioning valve Electromagnetically converts the output of the controller.
4 Pilot pump Supplies oil to the steering circuit.
Controls the pilot oil pressure to reduce the end shock. Also prevents the steering valve from relieving
5 Stop valve
at each steering end.
6 Steering valve Controls the operation of the steering cylinder with the pilot oil pressure.
7 Steering cylinders Controls the direction of the machine.
• The joystick steering system is a directional device used to turn the wheel loader by operating the joystick instead of the
steering wheel. The joystick is designed to reduce operator fatigue by allowing light touch steering operation with short
movement of the joystick.
• The joystick steering system consists of the electrical circuit, joystick, controller, joystick ON/OFF switch, hydraulic
circuit, solenoid proportional valve, stop valve, steering valve and joystick console, joystick position adjustment, and
armrest position adjustment.
2-48 WA900-3LC
OPERATION
STRUCTURE AND FUNCTION OF JOYSTICK STEERING SYSTEM
If the joystick switch is turned on, electrical current flows to
the joystick controller and makes it possible to operate the steering with
the joystick.
In addition, the directional (forward or reverse) operation of the

transmission can also be carried out from the directional lever by
operating the F N R button on the top of the joystick.
1. The steering and transmission control modes can be selected with joystick
switch (1) as shown below. The auto shift position can be selected only when the vehicle is
equipped with the auto shift function.The functional difference between steering with the
joystick system and the steering wheel is as follows:
Selection A B
Joystick Steering
ON - Steering with joystick OFF - Steering with steering wheel
ON/OFF switch
Steering with joystick

Steering Steering with wheel
Steering with wheel is also possible
FNR Operated with F/N/R buttons on joystick Operation with transmission control lever
Type Manual Auto Manual Auto
Control Manual Manual OFF Manual Manual

switch ON ON OFF
Speed range changing operation with shift up switch
Automatic change of speed range in accordance
Automatic change of speed range in accordance

and shift down switch on boom control lever
Speed range changing operation with shift

up switch and shift down switch on boom
Transmission
Operation with transmission levers
Operation with transmission lever
Selection of gear speed
with travel speed
with travel speed

control lever
WA900-3LC 2-49
OPERATION
A. Switch (A) changes the transmission to the manual mode. When
the switch is pressed once, the lamp (B) lights up and the system
is turned on, when the switch is pressed again, the lamp goes out
and the system is switched off.
OFF: Automatic gear shifting
ON: Gear shifting using transmission control lever up or down switch,

joystick steering only
B. When the joystick steering is on, it is possible to shift the speed

range between 1 and 3 with shift up switch (A) or shift down
switch (B) as shown in the table below.
Gear Shift Shift range

Lever Position 1 2 3
1st - C U ---- ----
2nd - D U U
3rd - E U U U
When the gear shift lever is in the 2nd or 3rd position, the speed range is
shifted from 2nd to 1st with the down shift switch. The travel speed range
is shifted up from the 1st to the 2nd automatically.
The combination of functions for switches (A) and (B) are as shown in the table below.
Steering Steering Wheel Joystick
Automatic
Transmission Automatic Manual Manual Manual Manual
switch OFF switch ON
A Hold ---- Hold Shift up Shift up
B Boom lever switch Kick down Kick down Kick Shift Shift down
[Only from 2nd] down down
The auto mode of the transmission is effective only when the vehicle is equipped with the automatic shift function.
2. Working with joystick and steering wheel
Because of the neutral interlock circuit, the forward and reverse directions of the transmission cannot be
changed if the forward/reverse lever and F/N/R button on the joystick are not in a neutral positions.
2-50 WA900-3LC
OPERATION
Using the joystick or steering wheel according to the type of work operations.
C. With joystick: Joystick is suitable for continuous loading work in a wide job site area with a relatively long cycle
time. Since the stroke of the joystick is short and the resistance is low, the operator is less fatigued even if they
operates the machine continuously.
D. With steering wheel: Since the operator can drive fast on a straight course and can control the steering wheel easily,
they can work efficiently among job sites and in load and carry operations. The steering wheel is also suitable for
short cycle time since the operator can hold the upper part of their body when changing direction.
E. The joystick console can be adjusted for the ease of operation. It is

possible to tilt or slide the console to position (D) by operating
lever (3).
For details on adjusting the joystick console, see “JOYSTICK CONSOLE

ADJUSTMENT” on page 2-55.
When exiting the cab, be sure to slide the joystick console

back. If the console is slid back, safety switch (4) is turned
off and operation of the joystick is automatically turned off
To prevent unexpected turning of the vehicle by use of the
joystick while the engine is running, be sure to slide the joy-
stick console backward.
OPERATION OF JOYSTICK STEERING
When operating with the joystick lever, always adjust the

angle of the steering wheel so it is possible to see the F N R
display on the left of the machine monitor.
F N R is also displayed on the two locations in the main monitor shown at

the right, this is synchronized with the F N R display and LED.
While F or R is displayed, the speed range is indicated on the N portion

also.
WA900-3LC 2-51
OPERATION
ADJUSTMENT OF STEERING WHEEL
Stop the machine before adjusting the angle of the steering

wheel.
This lever allows the steering column to be tilted forward or backward. Pull the lever up and move the
steering wheel to the desired position. Then push the lever down to lock the steering wheel in position.
Range of adjustment............ 125 mm (4.9 in) steps
Sit in the operator’s seat and pull lever (3) up to unlock the joystick con-
sole, slide the console from the rear position to the forward position, then
lock it securely in place. Under this condition, safety switch (4) is turned
on. Adjust joystick (1) to the angle for easy operation with console box
adjustment lever (2), see “JOYSTICK CONSOLE ADJUSTMENT” on
page 2-55.
Fasten the seat belt snugly around your hips.
Confirm joystick (1) operates in forward and reverse. Be sure lever (7) is in
a neutral position. Then, start the engine.
Check your work area, be sure all personnel are at least 7m (20ft) away
from every point on the machine.
Flip switch (8) to turn joystick control system on. If the directional
lever (7) has been set in the F or R position, the transmission is will be
set in the N (Neutral) position by the neutral interlock mechanism.
In this case, return the directional lever (7) to the N (Neutral) position, then
start your travel forward or reverse.
2-52 WA900-3LC
OPERATION
If joystick lever (1) is turned to the right, the vehicle turns to the right.
If the joystick lever is turned to the left, the vehicle turns to the left.
The more sharply the joystick is turned, the more quickly the
vehicle turns.
After the vehicle turns to the desired angle, return joystick lever (1) to
the N (Neutral) position. The joystick lever will automatically return to
the N (Neutral) position.
When returning the vehicle to a straight position, move the joystick in

the opposite direction from the N (Neutral) position.
Select the forward or reverse direction of the transmission with F/N/R

button (9) on joystick head (1).
Button N: Transmission is set to the neutral position at the moment

when this button is pushed.
Button F: Transmission is set to the forward position at

the moment when this button is pushed and released.
Button R: Transmission is set to the reverse position at

the moment when this button is pushed and released.
To change the speed range, use shift up switch (2) or shift down switch (3)
on the boom control lever.
Flip switch (8) to turn off joystick control system.
WA900-3LC 2-53
OPERATION
JOYSTICK STEERING PRECAUTIONS
If the vehicle or transmission cannot be operated normally with the joystick or if the warning lamp lights
up, stop the vehicle immediately. Turn the joystick steering switch off, and move machine to a safe place
using the steering wheel. Before operating the vehicle again, repair the trouble and confirm all functions
are normal. For troubleshooting and repair, contact your distributor. Never operate the vehicle until it is
repaired completely.
Do not move the joystick until the N display on the machine monitor
F/N/R display lights up indicating the joystick is ready. The joystick
controller will sense the neutral position.
If the joystick is moved before the neutral position is sensed, an error

will be detected and the caution lamp (1) will flash and the joystick
steering system will not work.
If an error is indicated, turn off the joystick control switch, and cycle
it on again.
If the vehicle is steered with the steering wheel, its turning angle will be
different from the joystick. If the vehicle is steered with the joystick
the control will be different. Since the feel of joystick steering is different
from the steering wheel, be careful until you are get accustomed to the
joystick.
If the F or R button is held on for more than 30 seconds, a short circuit

will be sensed and an error will be indicated. Be careful not to touch these
buttons when operating joystick, use them only when required.
If the forward/reverse lever is not in a neutral position, when the joystick

control switch is turned off, the neutral interlock circuit prevents
it from operating. Since the transmission is in a neutral position, the
vehicle cannot move forward or reverse. In this case, turn the
forward/reverse lever to the N (Neutral) position, then turn off the joy
stick control switch.
If the electrical circuit for the joystick steering system or transmission

control system has trouble, a centralized warning lamp (1) (Red) on the right side of the main monitor flashes to notify the
operator of problem. Since both steering systems and transmission are set in the respective neutral positions, turn off the
joystick control switch, then operate the vehicle with the steering wheel and forward/reverse lever.
2-54 WA900-3LC
OPERATION
JOYSTICK CONSOLE ADJUSTMENT
When adjusting, park the vehicle in a level and safe place. Adjust the console before starting any opera-
tions. Before adjusting the console, adjust the operator’s seat so the operator can reach the brake pedal
easily.
Adjustment of Joystick
Loosen lever (5) and move console forward, then tighten lever. Move
lever (2) forward and set joystick lever (1) to a desired position. After
setting, release lever (2).
Fore and Aft adjustment.....................130 mm (5.1 in) At knob top
Loosen lever (5) and move it back until joystick lever (1) contacts the
stopper, then tighten lever (5). In this way, joystick lever (1) can be set to
the desired position.
Adjusting the Height of the Left Armrest
Turn grip (6) to unlock the armrest, then set the armrest to a desired position. After setting, tighten the grip securely.
Vertical adjustment range.................................... 35 mm (1.38 in)
Sliding Console
When traveling or operating the work equipment, be sure to lock the console. Never adjust the console
while operating your machine.
When riding or exiting the vehicle, raise lever (1) and slide the console back. Do not stop the console halfway.
After operating the vehicle, be sure to slide the console to the forward stroke end and lock it in place.
WA900-3LC 2-55
OPERATION
AUTO SHIFT SYSTEM
METHOD OF OPERATING
Automatic gear shifting can be carried out in the 2nd to 3rd speed range
of the 3 forward and reverse speeds depending on the travel conditions.
Position A 1st speed
Position B 2nd speed
Position C 3rd speed
The range of speeds during automatic gear shifting is determined by the position of the gear shift lever as shown in the chart on
the right.
If the direction is changed between forward and reverse, the transmission automatically starts from the 2nd speed.
Remark
When the gear shift lever is in position A, the speed is fixed
in 1st. Automatic gear shifting is not operable. When shifting
down from 2nd to 1st, press the kickdown switch on the
boom control lever.
When traveling in any speed range, forward or reverse, if the travel

speed is less than 12 km/h (7.4 mph), the kickdown switch can be
actuated to shift down to 1st speed. In this way, it is made easy to carry
out load and carry operation.
To set the desired speed range when traveling uphill or downhill or

when carrying out grading operations, do as follows:
Press the HOLD switch on the boom control lever. The speed range of
the transmission will be shown on the main monitor display.
When shifting up or down from a set speed range, shift gears with
the gear shift lever.
Remark
When the transmission has been shifted down from 2nd to
1st with the kickdown switch, it will shift up from 1st to 2nd
when the travel speed increases.
2-56 WA900-3LC
OPERATION
PRECAUTIONS WHEN CHANGING DIRECTION
When changing travel direction, check your direction of

travel to be sure it is safe. There is a blind spot behind the
machine, be particularly careful when traveling in reverse.
Do not switch travel direction rapidly when traveling at high
speeds. When switching travel direction, slow down. Max
speed for changing direction: 12 km/h (7.5 mph)
There is no need to stop the machine when switching between forward (A)
and reverse (C). Place directional lever (1) in the desired position.
Changing direction between forward or reverse at high speeds will
decrease the transmissions life span.
If you attempted to change direction at a travel speed " the alarm

buzzer will sound for 3 seconds, rapidly.
If the alarm buzzer sounds, slow down immediately to reduce the

speed, then change direction between forward and reverse. If you
change direction $ the alarm buzzer will sound and at the same time
the controller will change. Be careful when decelerating the machine in
the ranges of # and "
F!"R Control for change of travel direction between forward

and reverse. Manual shift transmission
# Gear speed is changed as operated

" Gear speed is changed as operated & .
(Caution)
$ Gear speed is not changed as operated & caution, Controller controls gear speed according to travel speed.
WA900-3LC 2-57
OPERATION
F!"R Control for change of travel direction between forward and reverse. Manual shift transmission
.
# Gear speed is changed as operated

" Gear speed is changed as operated & (Caution).
$ Gear speed is not changed as operated & (Caution), Controller controls gear speed according to travel speed.
2-58 WA900-3LC
OPERATION
Down shifting at a high travel speed will decrease the life of the transmission. If you down shift at a high travel speed, the
warning buzzer sounds for 3 seconds intermittently and the controller controls the shifting operations according to the
following tables below.
Remark
If the gear shift lever is operated slowly or it is stopped between speed ranges, error code CALL may be
displayed. This is not a failure, the gear shift lever must be operated to complete the gear shifting within
2 seconds.
WA900-3LC 2-59
OPERATION
MAIN MONITOR FAILURE CODES
If an error code is displayed on the main monitor, (the speedometer display), follow the corresponding table when
carrying out self diagnostic procedures.
MAIN MONITOR DISPLAY

Diagnostic procedures chart for received error codes.
Error Transmission Control System Joystick Control System Action To Be

Alarm
Code Problem System Condition Problem System Condition Taken
Disconnection in Does not shift gears Disconnection, short Normal work

Returns to neutral
travel speed sen- automatically, or short to ground in possible
steering but steering
sor system switches to manual joystick FNNR with manual
wheel can be selected
gear shifting signal operations
E00 Disconnection, Normal opera- NO
Engine speed taken at
short or abnormal- tion with
2100 rpm. System
ity in engine speed ---- ---- joystick and
does not shift in auto
sensor steering in man-
shift
ual mode.
Disconnection,
short or short to Remains in N neutral
---- ----
ground in shift mode
lever system Stop machine,
turn ignition
Disconnection,
switch OFF
short or short to No travel, solenoid
---- ----
CALL ground in F, R signal output OFF YES
Restart
solenoid signal
machine, if error
Disconnection, message reoc-
short or short to curs, call service
No travel, solenoid
ground in speed ---- ----
signal output OFF
range solenoid sig-
nal
2-60 WA900-3LC
OPERATION
ERROR CODES INDICATED ON MAIN MONITOR
Transmission Control System
Auto and manual transmission control system.
Problem System
Error Code Item
Short Circuit Disconnection
10 Back up lamp relay U U

11 None --- ---
12 F Sol U U
13 R Sol U U
14 1st Sol U U
15 2nd Sol U U
16 3rd Sol U U
17 None --- ---
18 None --- ---
19in Joystick direction switch U U
20in Direction switch signal U U
21in Range switch signal U U
22in Travel speed sensor ✘ U
23in Engine speed sensor ✘ U
WA900-3LC 2-61
OPERATION
Joystick Control System
Includes joystick unit and machine body harness.
Problem System
Error Code Item
Short Circuit Disconnection
56 Joystick caution relay U ✵

57 Steering R Sol, detected when power is output U U
58 Steering L Sol, detected when power is output U U
59 Steering R short circuit at Sol HOT end U ✘
60 Steering L short circuit at Sol HOT end U ✘
61 Steering Sol cut relay U U
62in Abnormality in joystick neutral switch, for detection U U
range see separate sheet
63in Abnormality in joystick potentiometer U U
If trouble is detected, the joystick caution system will operate.
✵ Since E56 is kept turned on, breakage of the wire cannot be judged actually.
• Since E59 and E60 cannot be distinguished from each other due to design of the hardware, the alarms for each them are
turned on simultaneously.
STEERING COLUMN TILT LEVER
Stop the machine before adjusting the steering wheel angle.
This lever allows the steering column to tilt forward or backward.
Pull the lever up and move the steering wheel to the desired position. Then push the lever down to
lock the steering wheel in position.
Range of adjustment................................ 100 mm (3.9 in) steps
2-62 WA900-3LC
OPERATION
CAP LOCK
The fuel tank and hydraulic tank filler ports are equipped with locks.
Use the ignition key to open and close the caps as follows:
OPENING AND CLOSING CAPS WITH LOCKS

To Open the Fuel Tank Filler Port Cap
1. Insert the key into the cap. Ensure that the key is fully inserted or
the key could break.
2. Turn the key clockwise and align the mark on the cap with the
rotor groove. Remove the cap
To Lock the Cap.
1. Install the cap in place. Turn the key clockwise and take the key out.
To Open the Hydraulic Tank Filler Port Cap
1. Insert the key into the cap as far as the key will go. If it is turned
before inserting it all the way, the key could break.
2. Turn the key counterclockwise slowly and align the rotor groove
with the mark on the cap until a clicking sound is heard.
WA900-3LC 2-63
OPERATION
SAFETY BAR
Always use the safety bar when performing maintenance or

when transporting the machine. Remove the safety bar
during normal travel operations.
The safety bar is used during maintenance or when transporting

the machine. The safety bar locks the front and rear frames,
preventing them from pivoting.
BACKUP ALARM
This sounds an alarm when the directional lever is set
to the R position. It is used to warn people behind
the machine the machine is traveling in reverse.
DOOR OPEN LOCK

This can be used to hold the door open.
Open the door so lever (2) is aligned with groove lock (1), then pull knob (3) down. When
using the door open lock, be sure to apply the lock securely. When releasing the lock and
closing the door, push knob (3) up and insert pin (4) securely in the groove.
2-64 WA900-3LC
OPERATION
TOOL BOX
The tool box is installed in the brake component box of the left side
of the machine. Use it to store tools, etc.
FUEL STOP LEVER

This is used when the engine cannot be stopped even if the ignition
switch is turned to the OFF position. For normal operations, keep it
fully open.
If any abnormality occurs, turn fuel stop lever A to stop the supply of
fuel.
If the engine is stopped using the fuel stop lever, bleed the air from the cir-
cuit, before starting the engine again.
For details, see “FILTERS” on page 3-7.
SLOW BLOW FUSE

If the power does not come on when the ignition switch is turned on,the
slow blow fuse may be blown, check or replace the fuse. The slow blow
fuses are located on a bracket near the fan beside the engine on the right
side of the machine.
Slow Blow Fuses
• Main power......................................................120 Amp

• Battery power (ignition switch, hazard).............30 Amp
FUSES
Remark
Before replacing a fuse, be sure to turn off the ignition switch.
The fuses protect the electrical system from burning up. If the
fuse becomes corroded or white powder can be seen on the fuse or
fuse holder, replace the fuse. Replace fuse with proper rated
capacity. Never replace a fuse with a higher amperage fuse, damage to
the electrical system may result.
WA900-3LC 2-65
OPERATION
FUSE CAPACITY AND CIRCUIT
Fuse Box 1
No Capacity Circuit
1 20A Main lamp circuit
2 20A Back up lamp, brake lamp
3 10A Turn signal indicator lamp
4 10A Right head lamp
5 10A Left head lamp
6 10A Right side clearance lamp
7 10A Left side clearance lamp
8 10A Parking brake
9 10A Transmission control
10 10A Instrument panel
11 10A Work equipment positioner
12 10A Start switch
13 20A Hazard lamp
14 10A Spare
15 10A Auto greasing
Fuse Box 2
1 20A Front working lamp
2 20A Rear working lamp
3 30A Air conditioner 1
4 20A Air conditioner 2
5 20A Wiper and washer
6 10A Transmission controller
7 10A Cigarette lighter and radio
8 10A Rotating lamp
9 20A Side working lamp
10 10A Auto greasing
11 20A Left power window
12 20A Right power window
13 10A Air suspension seat
14 10A Spare
15 10A Spare
2-66 WA900-3LC
OPERATION
LUNCH BOX TRAY
There is a space for a lunch box at the right rear of the cab. A lunch
box 35 cm (13.8 in) long, 22 cm (8.7 in) wide and 18 cm (7.1 in) high
can be placed easily.
MANUAL STORAGE PLACE

Keep the manual in the operators seat rear pocket (1) for easy access when needed.
24V POWER FOR ACCESSORIES

The cigarette lighter (1) allows the operator a 24V power source.
Maximum electrical current is 7A.
12V POWER FOR ACCESSORIES

A 12V, 5A power supply is also provided inside of the left console.
WA900-3LC 2-67
OPERATION
PRECAUTIONS WHEN HANDLING ACCUMULATORS
Accumulators are charged with high pressure nitrogen gas,

which is extremely dangerous, read the following
procedures before handling accumulators
If any problem or failure occurs with the accumulators, contact your

distributor immediately.
Gas must be charged only by a qualified serviceman from your

distributor or by a person licensed to handle high pressure gas.
Never make holes or weld on accumulators.
Always release the gas before disposing of the accumulator or

disassembling it for maintenance.
Use the air bleed valve to release the gas.
Every 2000 hours or once a year, contact your distributor to have

the gas pressure checked.
The accumulators for the brakes are installed in the brake component
box on the left front side of the rear frame.
The accumulator for the PPC valve is installed on the right inside,
under the center platform. When handling the accumulator, be
extremely careful.
2-68 WA900-3LC
OPERATION
OPERATION
CHECKS BEFORE OPERATING THE MACHINE
WALK AROUND CHECKS
Leakage of oil or fuel or accumulation of flammable material around high temperature parts, such as the
engine mufflers or turbochargers, may cause fire. Carefully check for any abnormalities, if any are found,
repair them or contact your distributor immediately. Never operate a machine that is in need of repair.
Before starting the engine, look around and under the machine, check for loose nuts or bolts or leakage of oil, fuel or coolant.
Check the condition of the work equipment and hydraulic system. Check for loose wiring, play in components, collection of
debris in high temperatures places. Always carry out these items in this section before starting the engine each day.
1. Check for damage, wear, excess play in work equipment, cylinders, linkage and hoses. If any abnormality is found,
repair it immediately.
2. Remove any excess dirt or dust from around engine, battery, radiator. Check for any flammable material, leaves, twigs,
grass, etc. accumulated around the battery or high temperature engine parts, such as the engine muffler or turbocharger.
Remove all flammable material.
3. Check for leakage of oil from transmission case, axle, hydraulic tank, hoses, joints. If any abnormality is found, repair
it immediately.
4. Check for leakage of oil from brake lines. If any abnormality is found, repair it immediately.
WA900-3LC 2-69
OPERATION
5. Check for damage or excess wear on tires. Check for cracks or peeling of the tread. Check for cracks or wear to the wheel
sides rim, rim base, lock ring and loose mounting bolts. Tighten any loose wheel nuts. If any abnormality is found, repair
or replace the part. If any valve caps are missing, install new caps.
6. Check for damage to handrails or steps. Repair any damage and tighten any loose bolts.
7. Check for damage to gauges, monitor, loose bolts etc. If any abnormality is found, replace the parts. Clean any dirt off the
surfaces.
8. Check for loose air cleaner mounting bolts, tighten if necessary.
9. Check for loose battery terminals tighten any loose terminals.
10. Check seat belt and safety equipment
Even if there appears to be no abnormality with the seat belt,

always replace it once every three years.
Remark
The date of manufacture of the seat belt is marked on the belt
at the place indicated by the arrow in the diagram on the right.
Seat belt mounting bolts torque................... 24 Nm (18 lbf-ft)
If the belt is damaged, worn or if there is any deformation of the seat

belt holders, replace the seat belt with a new part immediately.
11. Check for loose bolts on ROPS
Check for any loose or damaged bolts (1). If any loose bolts are
found tighten them. If any bolts are damaged, replace them.
ROPS mounting bolts torque......... 2,452 Nm (1,808 lbf-ft)
12. Cab windows
Clean the cab window to ensure good visibility when operating your
machine. When cleaning the front window glass, stand on the central
step on the front frame. To move the central step, articulate the
machine and stand on the floor step of the cab and move to the central
step, supporting yourself by grasping the handrails of the cab.
2-70 WA900-3LC
OPERATION
13. Inspection of tires
If worn or damaged tires are used, they may burst and cause serious injury or death. To ensure safety,
do not use the following tires.
• Tires with a tread groove less than 15% of that of a new tire
• Tires with extreme uneven wear or with stepped type wear
• Tires where damage has reached the cords or with cracks in the rubber
• Tires with cut or pulled cords
• Tires with peeled, separated, surfaces
• Tires with a damaged bead
• Leaking or improperly repaired tubeless tires
• Deteriorated, deformed or abnormally damaged tires which do not seem usable
14. Inspection of rims
Check the rims, wheels and rings for deformation, corrosion

or cracks. In particular, check the side rings, lock rings and
rim flanges thoroughly.
CHECKS BEFORE STARTING YOUR WORK CYCLE
Be sure to put a warning tag on work equipment control

levers. Always carry out the items in this section before
starting the engine each day.
WA900-3LC 2-71
OPERATION
Check Monitor Panel
1. Turn the ignition switch to the ON position.
2. Check all monitor lamps, gauges and the warning lamps, be sure they
light up for about 3 seconds and the alarm buzzer sounds for about 1
second.
If any monitor lamp does not light, ask your distributor to inspect that
monitor lamp. Always carry out the items specified for the periodic mainte-
nance.
Check Coolant Level
Do not remove the cap while coolant is hot. Hot coolant may
spout out. When removing the radiator cap, slowly rotate the
cap to relieve the internal pressure.
1. Check coolant on level ground, be sure it is between the FULL and

LOW marks.
2. Open the access door on the left platform near the cab. Remove cap at
the top of the tank and add coolant. Tighten the cap securely.
For details, see “FUEL, COOLANT AND LUBRICANTS AMBIENT

TEMPERATURE CHART” on page 3-9.
Remark
If the volume of coolant is more than usual, check for possible
cylinder head leakage. Confirm there is no oil in the coolant.
2-72 WA900-3LC
OPERATION
Checking Oil Level in Engine and Adding Oil
1. Open the inspection door at the rear left side of the machine.
2. Remove dipstick and wipe the oil off with a cloth.
3. Insert dipstick fully, then take it out again.
4. The oil level should be between the H and L marks on dipstick.
5. If the oil level is below the L mark, add engine oil through oil filler.
For details of the oil to use, see “FUEL, COOLANT AND LUBRICANTS
AMBIENT TEMPERATURE CHART” on page 3-9.
6. If the oil is above the H mark, drain the excess engine oil from
drain valve and check the oil level again.
7. If the oil level is correct, tighten the oil filler cap securely, then
close the inspection window.
If the machine is at an angle, level it before checking.
WA900-3LC 2-73
OPERATION
Checking Brake Oil Tank Level, and Adding Oil
Always use engine oil to refill the brake oil tank.
1. On level ground check the brake oil level in the brake oil tank on
the left side of the machine be sure it is within sight gauge (1)
installed on the side of the brake tank.
A. When checking oil 10 hours or more after the engine is

stopped, use the upper level gauge in the figure at right.
B. When checking oil 5 minutes or more after the engine is

started, use the lower level gauge in the figure at right.
2. If the oil level is low, open the cover at the top of the platform,
then open cap and add engine oil.
For details of the oil to use, see “FUEL, COOLANT AND LUBRICANTS
Checking Fuel Level and Adding Fuel
When adding fuel, never let the fuel overflow. This may
cause a fire. If you spill fuel, thoroughly clean up any
spillage.
1. Turn the engine ignition switch to the ON position, then check the fuel
level with fuel gauge. After checking, return the ignition switch to the
OFF position.
2-74 WA900-3LC
OPERATION
2. Upon completion of work, remove the mud guard cover and add
fuel through filler until the fuel tank is full.
For details on opening and closing the cap, see “OPENING AND
CLOSING CAPS WITH LOCKS” on page 2-63.
For details on the fuel to use, see “FUEL, COOLANT AND LUBRI-
CANTS AMBIENT TEMPERATURE CHART” on page 3-9.
3. After adding fuel, tighten the cap securely.
Fuel capacity.................................... 1425 liter (376 gal)
Checking Electrical Wiring
If fuses are frequently blown or if there are traces of a short

circuit in the electrical wiring, locate the cause and carry out
repairs.
Accumulation of flammable material (dead leaves, twigs,
grass, etc.) around the battery may cause a fire, always
remove such debris.
Keep the top surface of the battery clean and check the vent
holes in the battery caps. If clogged with dirt or dust, wash
the battery top with a baking soda and warm water solution
followed by a mild soap wash.
Check for incorrectly rated fuses or any sign of disconnection or short circuit in the electrical wiring. Check for loose battery
terminals and tighten any loose parts.
Check the battery, starter motor and alternator wiring carefully. When carrying out a walk around check or pre-start checks,
always look for any accumulation of flammable material around the battery, if found remove such flammable material.
Contact your distributor for investigation and correction of the cause.
Check Tire Inflation Pressure
Check the tire inflation pressure with a tire pressure gauge while the tires are cool before starting work. Check for damage or
wear to the tires and rims. Check for loose wheel hub nuts (bolts). For proper inflation pressure, see TIRE PRESSURE in
section 2.
The appropriate tire inflation pressure differs according to the type of work, so see HANDLING THE TIRES in section 2. ★
WA900-3LC 2-75
OPERATION
Checking Parking Brake
Even if the parking brake switch (1) is turned ON, there is a

possible danger the machine may move. Wait until the
parking brake lamp (2) lights up, always keep brake pedal (3)
depressed until lamp is illuminated.
Parking brake switch (1).
Parking brake lamp (2). When lamp is illuminated, parking brake should
be set.
Hold brake pedal (3) down, place directional lever (5) in the N position
and turn switch (4) to the ON position to apply the parking brake.
Remark
Leaving the directional lever in the F or R position with
the engine off will not hold the machine in place. The
parking brake ON/OFF switch must be activated in order to
hold the machine in place when the engine is off.
2-76 WA900-3LC
OPERATION
MEASUREMENT CONDITIONS
• Tire inflation pressure................. Specified pressure

• Road surface.............. Dry pavement with 1/5 grade
• Machine.................................... Operating condition
METHOD OF MEASUREMENT
1. Turn the key switch (4) to the ON position and start the engine, set
the machine facing straight forward, then drive the machine up a
1/5 grade with the bucket empty.
2. Depress brake pedal (3), stop the machine, return directional lever
(5) to the neutral position, then stop the engine.
3. Set the parking brake switch (1) to ON position, release brake

pedal (3) slowly and check to see the machine is held in place.
Checking Effect of Brake
Drive the machine at a speed of 20 km/h (12.4 MPH) on a dry flat

concrete road surface and check the stopping distance, be sure it is less
than 7.5 m (24 ft 6 in).
OPERATOR’S SEAT
Park the machine in a safe place and stop the engine when
carrying out adjustment of the operators seat.
Adjust the seat before starting operations or when changing
operators.
Check and be sure you can fully depress the brake pedal
with your back against the seat backrest.
Adjustment (C) ride firmness requires the key switch to be in
the ON position to energize the electric air pump
A: FORE AND AFT SEAT MOVEMENT
Pull lever (1) up and move the seat to the desired position, then release
the lever.
Fore and aft adjustment..... 180 mm (7.1 in) 10 mm (0.4 in) x 18 stages
B: HEADREST HEIGHT
Move the headrest up and down to the desired height.
Adjustment range................................ 50 mm (2 in)
WA900-3LC 2-77
OPERATION
C: RIDE FIRMNESS
Sit on seat and adjust the strength of the suspension with valve (3).
Adjustment range........................... 50 to 120 kg (110 to (265 lb).
Push: Suspension is strengthened

Pull: Suspension is weakened
Remark
The seat height will be changed slightly when the firmness is
increased or decreased.
D: BACKREST ANGLE
Move lever (4) up and move the backrest to the front or rear. When
performing this, adjust your back to the seat back. If the seat back does
not fully contact your back, it may return suddenly.
Adjustment range................ 66° to front 3°x22 stages 72° to rear 3°x24

stages
Remark
If the seat back is reclined too far, the seat back may hit the
rear glass, use it in a position where it does not contact the
glass.
E: SEAT HEIGHT AND ANGLE
Move lever (2) up/down, then move the seat up or down as desired.
Since lever (2) is also used for adjustment seat angle, set the seat to
the desired height while adjusting the angle.
Adjustment range................................................................ 60 mm (2.4 in)
F: SEAT ANGLE
Pull lever (2) up and push down on the rear of the seat to tilt it backward. Move lever (2) down and push down on the front of
the seat to tilt it forward.
Adjustment range.................................. 13° Front tilt, rear tilt: 4 stages each
G: HEADREST ANGLE
Rotate the headrest to the front or rear.
H: ANGLE OF ARMREST
Adjust the angle of the armrest by rotating knob (5).

Adjusting range................................30° total Forward tilt 25° Backward tilt: 5°
Also, when the armrest is turned, it will spring up.
2-78 WA900-3LC
OPERATION
I: LUMBAR SUPPORT
The tension on the lower back can be adjusted by turning grip (6). There are five levels of support. Turn the knob in the
direction shown until the desired amount of lumbar support is achieved.
SEAT BELT
Always install a seat belt on machines equipped with ROPS.
Before fastening the seat belt, check the belt condition, belt
latch mechanism and the belts mounting brackets. If the belt
is worn or damaged, replace it.
Always fasten the seat belt before starting operations.
Always use the seat belt during operations.
Do not twist the left or right side of the seat belt when
fastening it.
FASTEN AND REMOVING SEAT BELT
Fasten the seat belt snugly around your hips without being too tight.
1. Sit on the seat, depress the brake pedal fully and adjust the seat so your back is against the backrest. After adjusting the
seat position, adjust tether belt (1). Adjust belt tension.
2. Pull the belt with your right hand and insert tongue (3) into buckle (2) securely until it clicks. When removing the belt,
press the red button on the buckle (2).
WRIST REST HEIGHT LEVER
The height of the wrist rest (1) can be adjusted easily with adjustment
lever (2). Turn adjustment lever in the direction (A) and adjust the
height of wrist lift rest properly, then turn adjustment lever to the fixed
direction (B).
WA900-3LC 2-79
OPERATION
REAR VIEW MIRRORS
Sit in the operators seat and adjust the rear view mirror so you can see
properly to the rear of the machine.
CHECKS BEFORE STARTING THE ENGINE
If the control levers are touched by accident, the work

equipment may move suddenly. When leaving the operator’s
compartment, always set the safety lever securely to the
LOCK position.
1. Check to be sure the parking brake switch (1) is in the ON position.
2. Check the directional lever (2), be sure it is in the N position. When

starting the engine, if the lever is not in the N position, the engine will
not start.
2-80 WA900-3LC
OPERATION
3. Lower the bucket to the ground, then check that work equipment
control levers (3), be sure they are locked with the safety lock (4).
4. Insert the key in ignition switch (5), turn the key to the ON
position and check the warning lamps, be sure they work.
Remark
When the ignition switch is turned to the ON position before
starting the engine, all monitor lamps, gauges and seconds, the
alarm buzzer will sound for approx. 1 second. When this
happens, 88 is displayed on the speedometer and 8 is displayed
on the transmission shift indicator. If the monitor lamps do not
light up, there is probably a failure or disconnection, contact
your distributor.
STARTING ENGINE
NORMAL STARTING CONDITIONS
Check to be sure there are no personnel or obstacles in the

surrounding area, sound the horn and start the engine.
Do not keep the starter motor engaged continuously for
more than 20 seconds. If the engine will not start, wait for at
least 2 minutes before trying to start the engine again.
1. Turn the key switch (1) to the START position to start the engine.
Remark
This machine is equipped with an engine pre-lube system. With
this feature, a noticeable time delay and pumping noise will
occur, while the engine lube passages are being filled and
pressurized, before engine cranking will begin. When an
adequate engine oil lube pressure is attained, the pump will stop
and engine cranking will begin.
WA900-3LC 2-81
OPERATION
2. When engine is started, release the key switch (1) and the key will
return automatically to ON position.
STARTING IN COLD WEATHER
Check be sure there are no personnel or obstacles in the

surrounding area, sound the horn and start the engine.
Never use starting aid fluids, they may cause explosions.
Do not keep the starter motor engaged continuously for
more than 20 seconds. If the engine will not start, wait for at
least 2 minutes before trying to start the engine again.
1. Turn the key in ignition switch (1) to the ON position. Preheating will
automatically start, and preheating lamp (2) will light up.
The table shown below gives a guide to preheating times.
Temperature C ° (F °) Pre-heating Time
0° to 10° C (0° to 50° F) 20 seconds
-10° to 20° C (14° to 68° F) 30 seconds
The preheating time in cold areas changes according to the coolant

temperature when starting the engine.
2-82 WA900-3LC
OPERATION
2. When the preheat lamp (2) is out, then turn the key switch (1) to the
START position to start the engine.
Remark
This machine is equipped with an engine pre-lube system. With
this feature, a noticeable time delay and pumping noise will
occur, while the engine lube passages are being filled and
pressurized, before engine cranking will begin. When an
adequate engine oil lube pressure is attained, the pump will stop
and engine cranking will begin.
3. When engine is started, release the key switch (1) and the key will
return automatically to the ON position.
OPERATIONAL CHECKS AFTER STARTING ENGINE

After starting the engine, do not start operations. First, carry out the
following operation and checks.
Remark
Do not suddenly accelerate the engine before the warm up
operation is completed. Do not run the engine at low or high
idle continuously for more than 20 minutes. If its necessary to
run the engine at idle, apply a load from time to time or run the
engine at a mid range speed.
1. Depress accelerator pedal (1) lightly and run the engine with no load
at midrange speed for about 5 minutes.
WA900-3LC 2-83
OPERATION
2. To warm up the hydraulic oil in cold areas, do as follows:
During the warm up operation, unlock the safety lock for the
work equipment control levers, move the bucket control lever in and
out of the TILT position to warm up the hydraulic oil. The relief time
in the tilt position should be a maximum of 10 seconds. Doing this
operation, the oil will reach the relief pressure and will warm up
the hydraulic oil quickly.
3. After carrying out the warm up operation, check the gauges

and caution lamps. If there is any abnormality, carry out maintenance
or repair immediately. Run the engine under a light load until engine
coolant temperature gauge (2) and torque converter oil gauge (3) are
in the green range.
4. Check for any abnormal exhaust color, sounds or vibrations. If there

is any abnormality, carry out repairs immediately.
MOVING THE MACHINE
When moving the machine, check the area around the

machine, be sure it is safe, sound the horn to warn all
personnel before starting.
Be sure all personnel are at least 7m (20ft) away from your
machine before starting your move.
Be aware of the blind spot behind the machine, especially
when traveling in reverse.
When moving the machine on slopes, set transmission
cutoff switch (1) in the OFF position, depress left brake
pedal (2) while depressing accelerator pedal (3), gradually
release left brake pedal to allow the machine to move.
2-84 WA900-3LC
OPERATION
1. Check all caution lamps (4) be sure they are not illuminated. If any are
illuminated, do not operate the machine, check out the problem and
make the proper repairs imedatly.
2. Raise safety lock (7) for bucket and (5) boom control lever (6) to the
FREE position.
3. Operate boom control lever (6) to set the work equipment to the travel
position (A).
Travel position (A)....................... 72 to 85 cm (28 to 34 in.)
4. Depress right brake pedal (8) and turn parking brake switch (9) to the
OFF position to release the parking brake. Keep right brake pedal
depressed.
Remark
If the parking brake is still actuated when parking brake switch (9)
is in the OFF position, cycle the parking brake switch ON, then
OFF again.
WA900-3LC 2-85
OPERATION
5. Set speed control lever (10) to the desired position.
Steering with the Wheel
6. Set directional lever (11) to the desired position.
Steering with Joystick
6. Engage the switch and lever (12).
For details, see “JOYSTICK STEERING” on page 2-48.
7. Release right brake pedal (8), then depress accelerator pedal (3) to
move the machine.
2-86 WA900-3LC
OPERATION
CHANGING GEAR SPEED RANGES
When traveling at high speeds, do not change gear speeds suddenly. When shifting gears, use the brakes
to reduce the travel speed, then shift gears. Failure to do so may damage the transmission.
Steering with the Joystick
To change speeds, see “JOYSTICK STEERING” on page 2-48.
Steering with the Wheel
Shift the gears as follows:
Set the speed control lever (1) to the desired position. Only 1st or 2nd
speeds are used for digging or loading operations, be sure to set the speed
control lever lock.
Remark
This machine is equipped with a kickdown switch that shifts the
gears down to 1st if the button at the tip of the boom control
lever is pushed when the machine is traveling in 2nd gear. We
recommend using the kickdown switch when carrying out dig-
ging or loading operations in 1st or 2nd gear.
Remark
If the gear shift lever is operated slowly or is stopped between
speed ranges, an error code CALL may be displayed. This is not
a failure, the lever must be operated smoothly with no hesitation
to complete the gear shifting process.
WA900-3LC 2-87
OPERATION
CHANGING DIRECTION
When changing direction between forward or reverse, check

your travel direction to be sure it is safe. Remember, there is
a blind spot behind the machine, always be particularly
careful when changing direction or traveling in reverse.
Do not switch between forward and reverse when traveling
at a high speeds.
When switching between forward or reverse, depress the
brake to reduce the travel speed sufficiently, then change
the direction of travel.
• 1st gear speed......................... 9 km/h (5.6 mph)
• 2nd gear speed....................... 12 km/h (7.5 mph)
• 3rd gear speed....................... 16 km/h (9.9 mph)
There is no need to stop the machine even when switching between

forward and reverse. Place directional lever (1) in the desired position.
Remark
If the gear shift lever is operated slowly or is stopped between
speed ranges, an error code CALL may be displayed. This is
not a failure, the lever must be operated smoothly with no
hesitation to complete the gear shifting process.
2-88 WA900-3LC
OPERATION
CHART FOR CHANGING TRAVEL DIRECTION
Changing travel direction or gear selection at high speeds will decrease the life of the transmission and torque converter. If you
try to change the travel direction in range " in the following table, the warning buzzer will sound for 3 seconds. If the warning
buzzer sounds, apply the brakes immediately to lower the speed to a safe range, then change the travel direction. If you try to
change the travel direction in range $ of the following table, the warning buzzer will also sound and the controller will shift
the transmission automatically. Be careful, the deceleration of the machine in this range is lower than in ranges # and "
F!"R Control for change of travel direction between forward and reverse. Manual shift transmission.
# Gear speed is changed as operated. " Gear speed is changed as operated & (Caution). $ Gear speed is not changed as
operated & caution, Controller controls gear speed according to travel speed.
WA900-3LC 2-89
OPERATION
TURNING
It is dangerous to turn the machine sharply at a high speed or to turn on steep hills.
If the engine stops when the machine is traveling, the steering cannot be used. This is particularly
dangerous on hills, never stop the engine when the machine is traveling. If the engine stops, stop the
machine immediately in a safe place.
STEERING WITH JOYSTICK
For details, see “JOYSTICK STEERING” on page 2-48.
STEERING WITH WHEEL
When traveling, use the steering wheel (1) to turn the machine. The front frame is joined to the rear
frame at a center point on the machine. The front and rear frames pivot at this point and the rear
wheels follow in the same tracks as the front wheels when turning. Turn the steering wheel lightly to
follow the rear of the machine as it turns. When turning the steering, do not turn it beyond the end of
it’s stroke.
STOPPING MACHINE
Avoid stopping suddenly. Give yourself ample room when

stopping.
Do not park the machine on slopes. If the machine has to be
parked on a slope, park it facing directly down the slope, and
dig the bucket into the ground, put blocks under the tires to
prevent the machine from moving.
Before leaving the operators compartment, always set the
safety lock lever securely in the LOCK position. If a control
lover is touched by accident, the work equipment may move
suddenly, this may lead to a serious accident.
Even if the parking brake switch is turned ON, there is danger
until the parking brake lamp lights up, keep the brake pedal
depressed.
Never leave a machine running and unattended, always turn
the engine off and park your machine properly when exiting
the operators compartment.
Never use the parking brake switch to stop the machine when traveling
except in an emergency. Apply the parking brake only after the machine
has stopped.
2-90 WA900-3LC
OPERATION
1. Release accelerator pedal (1) and depress brake pedal (2) to stop the
machine.
2. Place directional lever (3) in N (neutral).
3. Turn parking brake switch (4) on to apply the parking brake.
Remark
When the parking brake is applied, the transmission is
automatically returned to neutral.
OPERATION OF WORK EQUIPMENT

The boom (1) and bucket (2) control levers can be used to operate
the boom and bucket as follows:
WA900-3LC 2-91
OPERATION
BOOM OPERATION (LEVER 1)
A: RAISE The boom is raised up.
B: HOLD The boom is kept in the same position.
C: LOWER The boom is lowered down.
D: FLOAT The boom moves under its free weight.
When the boom control lever is pulled to its farthest position (A),
the lever will lock. When the boom reaches a preset position the lever will
return to the HOLD position and all functions will stop.
Remark
Never travel forward when the boom is in the FLOAT position.
The bucket leading edge will dig in, raise the machine up, or
stop the machine suddenly.The FLOAT feature should only be
used when traveling backwards, or backdraging.
Do not use the FLOAT position when lowering the bucket.
BUCKET OPERATION (LEVER 2)
A: TILT The bucket is tilted rearward.

BACK
B: HOLD The bucket is kept in the same position.
C: DUMP The bucket is tilted forward.
When the bucket control lever is pulled to its farthest position (A), the lever
will lock. When the bucket reaches a preset position the lever will return to
the HOLD position and all functions will stop.
2-92 WA900-3LC
OPERATION
TYPICAL WORK OPERATIONS
In addition to the following operations, it is possible to further increase the applications by using various attachments. Use
only Komatsu approved attachments on your machine.
BUCKET FILLING AND DIGGING OPERATIONS
Always have the machine facing square with the load when carrying out digging or scooping operation.
Never carry out these operations with the machine articulated. Never ram a load at high speeds with your
machine.
If the tires slip while loading the bucket the tire life will be reduced,
be careful not allow the tires to slip during operation.
• When loading piled soil or blasted rock, drive the machine forward
as follows to load. To prevent cutting the tires caused by tire
slipping, be aware of the following points during the operation:
• Always operate on a flat job site, remove any fallen rocks
that may damage or hinder your machines operation.
• When working with stock piles, operate the machine in 1st or
2nd; when loading blasted rock operate the machine in 1st.
1. When driving the machine forward and lowering the bucket, stop
bucket about 30 cm (12 in) from the ground, then lower it slowly.
Keep you bucket level with the ground when filling.
Remark
If the bucket hits the ground, the front tires will come off the
ground and the tires will slip.
2. Down shift immediately in front of your load when getting ready to

load the bucket. After completing the down shift, depress the
accelerator pedal at the same time and thrust the bucket into the load.
3. When material is stockpiled, keep the cutting edge of the bucket level
with the ground before entering pile. When loading blasted loose rock,
tilt the bucket down slightly before entering pile.
Be careful not to get large rocks under the bucket. This will make the front
tires raise up off the ground and slip. Try to keep the load in the center of
the bucket; if the load is on one side of the bucket, the load will be
unbalanced.
WA900-3LC 2-93
OPERATION
4. When entering into the material, raise and tilt the boom back slightly
to prevent the bucket from going in too far. By raising the boom,
ample traction will be produced by the front tires.
Remark
If the bucket is too deep in the material and the boom stops
rising or the machine stops moving forward, release the
accelerator pedal. Proper operation of the accelerator pedal for
each type of soil is important for saving fuel and preventing
unnecessary tire or machine wear.
5. Be sure there is enough material loaded in the bucket, tilt the bucket
back and raise the boom slightly.
Remark
If the bucket edge is rapidly moved up and down while loading,
the front tires will come off the ground and cause the machine to
jump.
6. If the bucket is too full, tilt it back and forth slightly to remove the
excessive material. This prevents spillover when traveling.
When digging with the bucket on level ground, set the bucket edge facing
down slightly as follows and drive the machine forward. Always be careful
not to load the bucket on one side, this will cause an unbalanced situation
with your load. This operation should be carried out in 1st gear.
Do not set the bucket edge facing down more than 20°.
1. Set the edge of the bucket facing down slightly.
2-94 WA900-3LC
OPERATION
2. Drive the machine forward, using the boom control lever cut a thin
layer of material off the surface each time when excavating the soil.
Be careful not to cut too much material as this may cause the tires to
slip.
3. Slightly operate the boom control lever up and down to reduce the
resistance when driving the machine forward.
• When digging with the bucket, avoid digging with one side of the
bucket.
LEVELING OPERATIONS
Remark
Always operate the machine in reverse when carrying out
leveling operations. If it is necessary to carry out leveling
operations when traveling forward, do not set the bucket angle
more than 20°. Never use the FLOAT feature when traveling
forward, the FLOAT feature should only be used when operating
in reverse.
1. Scoop some soil into the bucket. Move the machine backward while
spreading soil from the bucket little by little.
2. Go over the spread soil with the bucket teeth touching the ground and level the ground by back dragging with your
machine.
3. Scoop some more soil into the bucket, set the boom in the FLOAT position, level the bucket and smooth the ground by
traveling backward.
PUSHING OPERATION
Remark
Never set the bucket to the DUMP or FLOAT position when carrying out pushing operation.
1. When carrying out pushing operations, set the bottom of the bucket level with the ground surface.
2. Never push other equipment with the bucket of your machine.
WA900-3LC 2-95
OPERATION
LOADING AND CARRYING OPERATIONS
When carrying a load, lower the bucket to keep the center of

gravity low when traveling. Never travel with your load raised
high, this may cause your machine to tip or rollover.
The load and carry method for wheel loaders consists of a cycle of
scooping ⇒ hauling ⇒ loading. Always keep your travel path properly
maintained and clear.
When using the load and carry method, see “HANDLING THE TIRES” on page 2-104.
LOADING OPERATIONS
Select the method of operation which will give the minimum amount of turning and travel in order to provide the most effi-
cient method for the job site.
Always load in a flat working area. Never turn or apply the brake suddenly when traveling with a raised
load. Never travel with a load raised above 72 to 85 cm (28 to34 in).
Remark
If the tires slip, the tire life will be reduced. Do not allow the tires
to slip during operation. Avoid excessive sliding of the bucket.
Cross Drive Loading
Always set the wheel loader facing square to the stockpile. After digging in
and scooping up the load, drive the machine straight back in reverse, then
bring the dump truck in between the stock pile and the wheel loader. This
method requires the least amount of time for loading and is extremely
effective in reducing the cycle time.
V Shape Loading
Position the dump truck so the direction of approach is approximately 60°

from the direction of approach to the stockpile. After loading the bucket,
drive the wheel loader in reverse, then turn it to face the dump truck and
travel forward to load the dump truck. The smaller the turning angle of the
wheel loader, the more efficient the operation becomes. When loading a
full bucket and raising it to the maximum height, first shake the bucket to
stabilize the load before raising the bucket. This will prevent the load from
spilling to the rear.
2-96 WA900-3LC
OPERATION
Precautions When Piling up Loads
When forming products into a pile, be careful not to let the rear
counterweight come into contact with the ground. Do not set the bucket in
the DUMP position when carrying out piling up operations.
PRECAUTIONS FOR OPERATION

PERMISSIBLE WATER DEPTH
When working in water or on swampy ground, do not let the water come
above the bottom of the axle housing. After finishing the operation, wash
and check the lubrication points.
IF WHEEL BRAKE DOES NOT WORK
If the machine does not stop when the brake pedal is depressed, use the
parking brake to stop the machine.
Remark
If the parking brake has been used as an emergency brake,
contact your distributor to have the parking brake checked for
any abnormality.
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES
Lower the Center of Gravity When Turning.
When turning on slopes, lower the work equipment to lower the center of gravity before turning. It is dangerous to turn the
machine with the work equipment raised. If possible avoid working on slopes.
Braking on Downhill Slopes
If the service brakes are overused when traveling downhill, the brakes may overheated and fail. To avoid this problem, down
shift to a low range and make use of the engine braking force. When braking, use the right brake pedal.
If the speed control lever is not set in the proper speed position, the torque converter oil may overheat. To avoid this problem,
place the speed control lever in the next lower gear range to lower the oil temperature. If the converter temperature gauge is
not indicating in the green range on the scale even with the lever in the 1st speed position, stop the machine, place the lever in
neutral and run the engine at medium speed until the gauge returns to the green range.
If Engine Stops
If the engine stops on a slope, depress the right brake pedal, lower the work equipment to the ground and apply the parking
brake. Put the directional and speed control levers in neutral and start the engine again. If the directional lever is not in neutral,
the engine will not start.
WA900-3LC 2-97
OPERATION
PRECAUTIONS WHEN TRAVELING WITH YOUR MACHINE
When the machine travels at a high speed for a long distance, the tires become extremely hot. This causes early tire wear, high
speed travel should be avoided as much as possible. If the machine must be driven for a long distance, take the following
precautions.
• Follow all safety and OSHA regulations relating to your machine and your companies policies. Stay alert and drive
carefully.
• Before operating your machine, carry out all checks before starting. Check your machine and work area for any hazards or
unstable conditions.
When driving the machine continuously, use the following as a guideline for one days travel:
(Travel distance. within 20 km (12 miles); travel time: Max. 1 hour)
• When the machine is stopped, check the tires and all other parts for any abnormalities, check the oil and coolant levels, if
any problems or abnormalities are found, have them corrected immediately.
• Never operate a machine that is in need of repair.
• Check the tire pressure before starting work operations, when the tire is cool at the start of your work shift.
• Always travel with the bucket empty. Never travel with the bucket above the traveling height of 30 cm (12 in) off the
ground
• Never use calcium chloride or dry ballast in the tires.
• Always travel at a safe speed, this is a speed where you can control or stop the machine in an emergency.
• Keep in mind all pedestrians, work personnel or smaller equipment have the right away over your machine, a loaded
machine has the right away over an unloaded machine.
• Use your horn to warn all personnel in the area of your travel, slow down when approaching any blind areas and sound
your horn.
• When traveling be sure all personnel are at least 12m (40 ft) away from your machine.
• Slow down when approaching a sharp turn. Taking turns too fast may overturn your machine.
• Stay alert, keep your mind on your job and never get involved in horseplay.
2-98 WA900-3LC
OPERATION
ADJUSTING WORK EQUIPMENT
Stop the machine on flat ground and put blocks in front and
behind the wheels. Apply the parking brake. Turn the engine
OFF Secure the front and rear frames with the safety bar.
Never stand or work under the work equipment when the arm
is raised.
The boom kick out makes it possible to set the boom so it automatically
stops at the desired lifting height, the bucket positioner makes it possible to
set the bucket so it automatically stops at the desired digging angle. The
settings can be adjusted to match the working conditions.
When making any adjustments or repairs to the machine, the

work levers should be taged and the ignition key should be
removed and held by the person making the repairs or
adjustments.
ADJUSTING BOOM KICKOUT
1. Raise the bucket to the desired height, set the boom control lever at
HOLD and lock the lever in position. Then stop the engine, take the
ignition key out of the ignition and adjust as follows.
2. Loosen two bolts (1) and adjust plate (2) so the bottom edge is in line
with the center of the sensing surface of the switch (3). Then tighten
the bolts to hold the plate in position.
WA900-3LC 2-99
OPERATION
3. Loosen two nuts (4) to make a clearance of 3 to 5 mm (0.12 to 0.20 in)
between plate (2) and the sensing surface of the switch (3).
Then tighten the nuts to hold in position.
Torque.............................................. 2.0 Nm (18 lbf-in)
4. After adjusting, start the engine and operate the boom control lever.
Check the lever to see if it automatically returns to the HOLD position
when the bucket reaches the desired height.
ADJUSTING BUCKET POSITIONER
1. Lower the bucket to the ground and adjust the bucket to the desired
digging angle. Set the bucket control lever at HOLD, stop the engine,
take the ignition key out of the ignition and adjust as follows.
2. Loosen two bolts (1) and adjust mounting bracket (4) of the switch so
that the rear tip of angle (2) is in line with the center of the sensing
surface of the switch (3). Then tighten the bolts to hold the bracket in
position.
3. Loosen two nuts (5) and adjust to set a clearance of 3 to 5 mm

(0.12 to 0.20 in) between angle (2) and the sensing surface switch (3).
Then tighten the nuts to hold in position.
Torque.......................................... 2.0 Nm (18 lbf-in)
4. After adjusting, start the engine and raise the boom. Operate the
bucket control lever in the DUMP position, then operate it in the
TILT position and check the bucket control lever to see if it
automatically returns to the HOLD position when the bucket reaches
the desired setting.
BUCKET LEVEL INDICATOR
A and B at the top rear of the bucket are the level indicators, the bucket
angle can be checked during operations.
A: Parallel with cutting edge
B: 90° to cutting edge
2-100 WA900-3LC
OPERATION
PARKING THE MACHINE
Avoid stopping suddenly. Give yourself ample room when

stopping.
Never park the machine on slopes. If the machine has to be
parked on a slope, set it facing directly down the slope, dig the
bucket into the ground and place blocks under the tires to
prevent the machine from moving.
Before leaving the operators compartment, always set the
safety lock lever in the LOCK position. If the control levers are
touched by accident, the work equipment or the machine may
move suddenly, this may lead to a serious accident.
Never leave the machine running and unattended, Always shut
the engine off when leaving the operators compartment.
Even if the parking brake switch is turned ON, there is a
danger until the parking brake lamp lights up, keep the brake
pedal depressed.
Remark
Never use the parking brake switch to stop the machine when
traveling except in an emergency. Apply the parking brake only
after the machine has stopped.
1. Release accelerator pedal (1) and depress brake pedal (2) to stop the
machine.
2. Place directional lever (3a) in N (neutral) position.
WA900-3LC 2-101
OPERATION
3. Press N (neutral) button (3b) to place transmission in neutral when
steering with joystick.
4. Turn parking brake switch (4) to ON position to apply the parking

brake.
Remark
When the parking brake is applied, the transmission is
automatically returned to neutral.
5. Operate boom control lever (5) to lower the bucket to the ground.
6. Lock boom and bucket lever (5) and (6) with safety lock (7).
2-102 WA900-3LC
OPERATION
CHECKS AFTER OPERATION
Check the engine coolant temperature, engine oil pressure, torque
converter oil temperature and fuel level with the meters and lamps. If the
engine has overheated. Run the engine at a midrange speed to allow the
engine to cool down before stopping it.
STOPPING ENGINE
If the engine is abruptly stopped before it has cooled down, engine life may
be shortened. Avoid stopping the engine too early after working, except for
an emergency. In particular, if the engine has overheated.
1. Run the engine at a low idle speed for about 5 minutes to allow it to
gradually cool down.
2. Turn the key switch (1) to the OFF position and stop the engine.
Remove the key from ignition switch.
CHECKS AFTER STOPPING THE ENGINE

1. Walk around the machine and check the work equipment and body.
Check for leakage of oil and water. If any leakage or abnormality is
found, carry out repairs immediately.
2. Fill the fuel tank.
3. Remove any waste paper, debris or dead leaves from the inside of the
engine compartment. These may cause a fire.
4. Remove any mud stuck to the under side of the machine.
WA900-3LC 2-103
OPERATION
LOCK AND SECURE LOCATIONS
Always lock the following places.
(1) Engine side panel (left, right)
(2) Cab door (left, right)
(3) Engine hood at rear of cab (2 points)
(4) Fuel tank filler cap
(5) Hydraulic tank filler cap
Remark
The ignition switch key is also used for the locks.
HANDLING THE TIRES

PRECAUTIONS WHEN HANDLING TIRES
If a tire has reached any of the following service limits, there is

danger the tire may fail or cause an accident, to ensure safety,
replace it with a new tire.
• Service limits for wear

• When the remaining depth of the groove on construction
equipment tires (at a point approx. ¼ of the tread width) is 15% of
the groove depth on a new tire.
• When the tire shows marked uneven wear, stepped wear or other
• abnormal wear or when the cord layer is exposed.
• Service limits for damage

• When there is external damage extending cord or when the cord is (1) Breaker or belt (cord layer)
broken (2) Tread
• When the cord is cut or there is dragging (3) Shoulder
• When the tire is peeling (there is separation) (4) Side wall
(5) Carcass
• When the bead is damaged
(6) Inner liner
• For tubeless tires, when there is air leakage or improper repair (7) Bead
It is dangerous to jack up the machine without proper equipment and experience.

Always contact your distributor when replacing the tires.
2-104 WA900-3LC
OPERATION
TIRE PRESSURE
Measure the tire pressure before starting operations, when the tires are cool. If the tire inflation pressure is too low, they will be
overload; if it is too high, it will cause cuts and shock burst. To prevent these problems, adjust the tire inflation pressure
according to the table below.
H-h
Deflection ratio = x 100
H
As a guideline tires can be checked visibly, the deflection ratio of the front tire, deflection/free height, is as follows:
• When carrying normal load, boom horizontal.........10 - 15%

• When digging, rear wheels off ground.....................20 - 25%
When checking the tire inflation pressure, look for small scratches, peeling of the surface, nails or pieces of metal which may
cause punctures and for any abnormal wear. Remove any stones or rocks from the tread area. Maintaining the surface will
extend the tire life and give you improved economy.
• For operations on normal road surfaces, rock digging operations

★ High end of range in air pressure chart
• Stockpile operations on soft ground
★ Average pressure in air pressure chart
• Operations on sand, operations not using much digging force
★ Low end of range in air pressure chart
If the deflection of the tire is excessive, raise the inflation pressure within the limits given in the table, see the deflection ratio.
Inflation pressure
Ply rating
Maker
Tire size (pattern) Soft or sandy ground Normal ground
Stockpile Digging Stockpile Digging

Free height mm (in)
45/65-45 L5 DL2 46 B 679 4.25 to 4.75 kg/cm² 4.75 to 5.25 kg/cm² 4.75 to 5.25 kg/cm² 4.75 to 5.25 kg/cm²
(60.3 to 67.5 psi) (67.5 to 74.5 psi) (67.5 to 74.5 psi) (67.5 to 74.5 psi)
45/65-45 L5 46 B 679 4.25 to 4.75 kg/cm² 4.75 to 5.25 kg/cm² 4.75 to 5.25 kg/cm² 4.75 to 5.25 kg/cm²
45/65-45 L5 46 679 4.25 to 4.75 kg/cm² 4.75 to 5.25 kg/cm² 4.75 to 5.25 kg/cm² 4.75 to 5.25 kg/cm²
45/65-45 L5 46 679 4.25 to 4.75 kg/cm² 4.75 to 5.25 kg/cm² 4.75 to 5.25 kg/cm² 4.75 to 5.25 kg/cm²
XL Front 5.6 kg/cm² Front 5.6 kg/cm² Front 5.6 kg/cm² Front 5.6 kg/cm²
(80 psi) (80 psi) (80 psi) (80 psi)
45/65-R45 DD M -------- Rear 3.2 kg/cm² Rear 3.2 kg/cm² Rear 3.2 kg/cm² Rear 3.2 kg/cm²
2 (45 psi) (45 psi) (45 psi) (45 psi)
Stockpile operations means loading sand or other loose materials.

B = Bridgestone T = Toyo G = Goodyear M = Michelin
WA900-3LC 2-105
OPERATION
PRECAUTIONS WITH LOAD AND CARRY OPERATIONS
When traveling continuously during load and carry operations, choose the correct tires to match the operating conditions or
choose the operating conditions to match the tires. If you fail to do this, the tires will be damaged, contact your distributor or
tire dealer when selecting tires for specific operations.
BUCKET REMOVAL AND INSTALLATION
Park the machine on level ground, lower the bucket, shut down the engine before starting procedures.
Remove or install the bucket in the following manner:
Set safety bar (1) on the frame
Apply the parking brake (2)
Place blocks (3) under the tires.
2-106 WA900-3LC
OPERATION
REMOVING THE BUCKET
1. Remove mounting bolt (4).
2. Sling the bucket link, then pull bucket link pin (5) out. Secure the
bucket link safely.
3. Remove mounting bolt (6).
4. Pull bucket pin (7) out on both sides of the bucket.
WA900-3LC 2-107
OPERATION
5. Disconnect boom from bucket.
INSTALLING THE BUCKET
Align the pin holes with each other by using a drift rod. Never
use your hands or finger to align the pin holes.
1. Set cord ring (2) on top of boom boss (1) as shown.
Remark
After assembly of the bucket and adjustment with shims, move
the cord ring down to the groove.
2. Coat dust seal lip portion (3) with grease.
3. Align the left and right bucket pin holes.
4. Select the number of shims so clearance A between bucket hinge boss

(4) and boom boss (1) are < 1 to 1.5 mm (0.04 - 0.06 in).
2-108 WA900-3LC
OPERATION
5. Assemble the shims, align the pin holes, then insert bucket hinge pin
(5). Coat pin and pin hole with grease to prevent damage to the dust
seal when inserting the bucket hinge pin. Use a bucket hinge pin that
has a grease hole.
6. Install mounting bolt (6).
7. Use the same procedure as in steps 1 through 7 to install the bucket

link pin. Assemble the pin so the grease hole is not at the bucket link.
Coat the bucket hinge pin and bucket link pin with grease. For details, see
“EVERY 100 HOURS OF SERVICE” on page 3-52.
TRANSPORTATION
When transporting your machine, contact your distributor, observe all laws and regulations to ensure safety during the opera-
tion.
LIFTING MACHINE
The machine must be disassembled before the chassis can be lifted, contact your distributor to have the machine disassembled.
WA900-3LC 2-109
OPERATION
COLD WEATHER OPERATION
PRECAUTIONS FOR LOW TEMPERATURES
If the temperature drops and it becomes difficult to start the engine and the coolant may freeze.
FUEL AND LUBRICANTS
Change to low viscosity fuel and oil for all components. For details of the specified viscosities, see “FUEL, COOLANT AND
LUBRICANTS AMBIENT TEMPERATURE CHART” on page 3-9.
COOLANT
Never use methanol, ethanol or propanol based antifreeze.
Never use any water leak preventing agents or independently mix them with an antifreeze.
Do not mix one antifreeze with a different brand.
Never use flammable liquids as an engine coolant.
For details of the antifreeze mixture when changing the coolant, see “WHEN REQUIRED” on page 3-24.
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the standard
requirements as shown below. With permanent antifreeze, no change of coolant is required for a year. If it is doubtful that an
available antifreeze meets the standard requirements, ask the supplier of that antifreeze for information.
Standard requirements for permanent antifreeze

• SAE........................................................... J 1034
• FEDERAL STANDARD...................... O-A-548D
Remark
Where no permanent antifreeze is available, an ethylene glycol antifreeze without corrosion inhibitor may be
used only for the cold season operation. In this case, clean the cooling system twice a year (in spring and
autumn). When refilling the cooling system, add antifreeze in autumn, but do not add any in spring.
BATTERY
To avoid gas explosions, do not bring fire or sparks near the battery. Battery electrolyte is dangerous.
If it gets in your eyes or on your skin, wash it off with large amounts of water and consult a doctor
immediately.
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the battery
electrolyte may freeze. Maintain the battery charge as close as possible to 100% and insulate it against cold temperature so the
machine can be started easily the next morning.
2-110 WA900-3LC
OPERATION
PRECAUTIONS AFTER WORK COMPLETION
To prevent mud, water or the undercarriage from freezing and making it impossible for the machine to move on the following
morning, always observe the following precautions.
• Mud and water on the machine body should be completely removed. This is to prevent freeze damage to the seals.
• Park the machine on hard, dry ground. If this is not possible, park the machine on wooden boards. The boards help protect
the tire tread from being frozen in the soil.
• Fill the fuel tank to prevent moisture from collecting inside the tank.
• Open the drain valve and drain any water collected in the fuel system to prevent freezing.
• As the battery capacity drops in low temperatures, cover the battery or remove it from the machine, keep it in a warm
place and reinstall it the next morning.
AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as follows:
Replace the fuel and oil for all parts with oil of the viscosity specified. For details, see “FUEL, COOLANT AND LUBRI-
CANTS AMBIENT TEMPERATURE CHART” on page 3-9. If for any reason permanent antifreeze cannot be used and an
ethyl glycol base antifreeze (winter, one season type) is used instead, drain and clean the cooling system thoroughly and fill
with fresh distilled water.
WARM UP OPERATION FOR HYDRAULIC STEERING CIRCUIT IN COLD WEATHER
f the steering wheel is turned and stopped while the oil

temperature is low, it may take some time for the vehicle to
stop turning. In this case, perform the warm up operations in
a wider place, secure the safety bar. Do not relieve the
hydraulic oil in the circuit continuously for more than 5
seconds.
When the temperature is low, do not start the operation of the vehicle soon
after starting the engine.
Warm up the hydraulic steering circuit; slowly turn the steering wheel to the right and left to warm up the oil in the steering
valve. Repeat this operation for about 10 minutes to warm up the oil.Turn the steering wheel a little and stop. Then, confirm
that the vehicle is steered by the angle equivalent to the turning angle of the steering wheel.
Recommended oil; Select the oil depending on the temperature as shown in the following table:
Temperature °C (°F)
Type Of Oil
-30 (-22) -20 (-4) -10 (14) 0 (32) 10 (50) 20 (68) 30 (86)
SAE10WCD
Hydraulic oil Engine oil
SAE5W-20CD
Even if SAE5W-20CD is used in low temperature areas, always carry out the warm up operation without fail.
If SAE5W-20CD is used in a cold season, replace it with SAE-10WCD after the cold season.
WA900-3LC 2-111
OPERATION
LONG TERM STORAGE
BEFORE STORAGE
When placing the machine in storage for a long time period, do as follows:
• After machine is washed and dried, house the machine in a dry building. Never leave it outdoors. If the machine must be
left outdoors, park it on well drained concrete and cover it with canvas, etc.
• Completely fill the fuel tank, lubricate and change the oil before storage.
• Apply a thin coat of grease to the metal surface of the hydraulic piston rods.
• Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately.
• If the ambient temperature is expected to drop below 0° C, always add antifreeze to the coolant.
• Apply the safety locks to the bucket control lever, boom control lever and directional lever, then apply the parking brake.
DURING STORAGE
If you carry out the rust prevention procedures while the machine is indoors, open the doors or windows
to improve ventilation. Always work in a well ventelated area.
Run the engine and operate the controls once a month so a new film of oil will coat the movable parts and component surfaces.
Use a 1 amp trickle charger to charge the battery. Before operating the work equipment, wipe off the grease on the hydraulic
piston rods. Operate the air conditioner for 3 to 5 minutes once a month to lubricate each portion of its compressor. Be sure to
idle the engine at low speed.
AFTER STORAGE
If the machine is stored without carrying out the monthly rust prevention operation, contact your distributor for service before
starting the machine.
Carry out the following procedure when taking the machine out of long term storage:
• Wipe off the grease from the hydraulic cylinder rods.
• Check all fluids and add if needed.
• Check air pressure in the tires.
• Lubricate all lubrication points on the machine.
2-112 WA900-3LC
OPERATION
BASIC TROUBLESHOOTING
WHEN MACHINE RUNS OUT OF FUEL
Before attempting to troubleshoot any system on your

machine carefully check your work area to be sure it is safe
before cranking the engine.
If the machine has run out of fuel, add fuel and then bleed the air from the
fuel system before starting the engine.
PROCEDURES FOR BLEEDING AIR FROM FUEL SYSTEM
1. Crack outlet line at filter header.
2. Use the primer pump to remove air from the filters through the outlet
line. After air is removed, tighten the outlet line.
Remark
Never use starting ether to pre-start the engine. These starting
aids are highly flammable and could explode and cause injury or
damage the engine if improperly used.
MAINTENANCE ON A/C SYSTEM

When storing the machine for a long period of time (1 month or longer).
When using the compressor after storing the machine or leaving the air conditioner unused for a long time (1 month or longer),
warm the inside of the cab to at least 10° C by running the engine at an idle, then operate the air conditioner in the max cool
mode. Check the temperature of the air coming out of the air ducts. If it is sufficiently cold and there is no abnormal noises
coming from the compressor the system is operating properly.
If there is a problem with the machines air conditioner system, shut it down and contact your dealer as soon as possible.
WA900-3LC 2-113
OPERATION
TOWING THE MACHINE
If the machine is towed in the wrong way, serious injury or damage may occur. If there is a failure in the
braking system and the brakes cannot be used, be extremely careful when towing.
Remark
Towing is for moving the machine to a place where inspection and maintenance can be carried out and not for
moving it long distances. Never tow the machine long distances.
When towing the machine, take the following precautions:

• When releasing the brakes, put blocks under the wheels to prevent the machine from moving. If the wheels are not
blocked, the machine may suddenly move.
• When towing a machine, tow it at a low speed of less than 2 km/h (1.24 mph) and for a short distance only. The machine
should be towed in emergency situations. If the machine must be moved long distances, use a transporter.
• Install a guard plate on the machine being towed to protect the operator if the tow rope or bar should break.
• Never let anyone ride on your machine.
• Check to be sure the tow rope or bar is of ample strength for the weight of the machine being towed. Since the machine
being towed may need to travel through mud or up hills, use a tow rope or bar of sufficient strength.
• Keep the length of the tow rope as small as possible. Keep the angle between the center lines of the two machines to
within 30°.
• If the machine is jerked suddenly, an excessive load will be applied to the tow rope or bar causing it to break. Always
move the machine slowly at a fixed speed.
• The towing machine should be of the same size and power as the machine being towed. Check the towing machines
braking power, weight and rim pull to allow for control of both machine on slopes or on the tow road.
• When towing a machine downhill, use a larger machine for towing to provide ample rim pull and braking power or
connect another machine to the rear of the machine being towed. In this way it is possible to prevent the machine from
losing control and turning over.
• Towing may be carried out under differing conditions, it is impossible to determine beforehand the requirements for
towing. Towing on flat horizontal roads will require the minimum rim pull, while towing on slopes or on uneven road
surfaces will require the maximum rim pull.
2-114 WA900-3LC
OPERATION
WHEN ENGINE POWER CAN BE USED
• If the transmission and steering wheel can be operated and the engine
is running, it is possible to tow the machine out of mud or to move it
for a short distance to the edge of the road.
• The operator should operate the machine being towed in the direction
the machine is towed.
WHEN ENGINE POWER CANNOT BE USED
When towing a machine with the engine stopped, use the following
procedures. If leakage in the brake circuit has caused the pressure to drop,
the parking brake will be applied. When towing the machine, release the
parking brake.
1. The transmission oil does not lubricate the system, remove the front
and rear drive shafts. If necessary, block the tires to prevent the
machine from moving.
2. When the steering cannot be operated, remove the steering cylinder

and linkage. Even if the brakes are in good condition, the brakes can
only be used a limited number of times. The braking force is reduced
each time the pedal is depressed.
3. Connect the towing equipment securely. When carrying out towing

operations, use two machines of at least the same class as the machine
being towed. Connect one machine each to the front and rear of the
machine being towed, then remove the blocks from the tires and tow
the machine.
RELEASING PARKING BRAKE
Stop the machine on a flat surface when releasing the parking

brake and check the surrounding area. In emergencies or
when the parking brake must be released on a hill, block the
tires before releasing the brake. When the parking brake is
released, no braking force can be applied, carefully check the
situation to be sure it is safe when moving the machine.
1. The parking brake is released by the accumulator oil pressure. If the

accumulator pressure is too low, release the parking brake
mechanically, then tow the machine.
2. Turn adjustment screws on the side of the slack adjuster. Turn (A)
clockwise and (B) counterclockwise to retract rod (2) of spring
cylinder (1) to loosen plate (3).
3. Turn screws (A) clockwise and (B) counterclockwise by ½ turn

intervals. This releases the parking brake.
WA900-3LC 2-115
OPERATION
EMERGENCY TRAVEL OPERATION
The normal gear shifting operation is carried out by electrical signals. If there should be a failure in the electrical system and
the machine will not move, it is possible to move the machine by using the following procedure.
Always contact your distributor to carry out emergency travel operations.
IF BATTERY IS DISCHARGED
When checking or handling the batteries, stop the engine and turn the ignition switch to the OFF position
before starting.
Before starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the
battery. If battery tops are badly corroded, clean with diluted baking soda and ward water solution.
The battery generates hydrogen gas, there is danger of explosion. Do not bring lighted cigarettes near the
battery or do anything that will cause sparks. Battery electrolyte is dilute sulfuric acid and it will attack
your clothes and skin. If it gets on your clothes or on your skin, wash it off immediately with large
quantities of water. If it gets in your eyes, flush your eyes with large quantities of fresh water and consult a
doctor immediately. When handling batteries, always wear protective goggles and rubber gloves.
When removing the battery, first disconnect the cable from the ground, negative terminal. When installing,
connect the positive terminal first. If a tool touches the cable connecting the positive terminal and the
chassis, there is danger it will cause sparks.
If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an
explosion. When installing the terminals, install them tightly. When removing or installing, check battery
terminal polarity. first
REMOVAL AND INSTALLATION OF BATTERY
When removing the battery, first disconnect the cable from the
ground, negative terminal. If a tool touches a cable connecting the
positive terminal and the chassis, there is danger of sparks being
emitted. When installing the battery, the ground cable should be
connected to the ground terminal as the last step.
Remark
There are two batteries each (total: 4) on both sides at the
rear of the machine.
PRECAUTIONS FOR CHARGING BATTERY
Charging Battery When Mounted on Machine
Before charging, disconnect the cable from the negative terminal of the
battery. The unusually high voltage will damage the alternator. While
charging the battery to avoid gas explosions, do not bring fire or sparks
near the battery. If electrolyte temperature exceeds 45°C, stop charging for
a while. Turn off the charger as soon as the battery is charged.
Overcharging the battery may cause overheating, decreasing the quantity
of electrolyte or damaging the electrode plates.
Do not mix the cables, positive to negative or negative to positive, as it will

damage the alternator. When performing any service to the battery besides
checking the electrolyte level or measuring the specific gravity, disconnect cables
from battery.
2-116 WA900-3LC
OPERATION
Remark
The batteries are on both sides at the rear of the machine. The battery used for the ground is on the left side of
the machine.
STARTING ENGINE WITH BOOSTER CABLE
When starting the engine with a booster cable, do as follows:

Precautions When Connecting/ Disconnecting Booster Cable
When connecting the cables, never cross the positive and

negative terminals.
When starting the engine with booster cables, always wear
safety glasses.
Be careful not to let the machines touch each other, sparks
from the contact could ignite the hydrogen gas.
Make sure there is no mistakes in the booster cable
connections. The final connection should be at the engine
block of the machine.
Use care when removing the cables from the machine that has
been started. Do not allow the cable ends to contact each
other or the machine, to avoid hydrogen explosion.
• The size of the booster cable and clip should be suitable for the battery size.
• Check the cables and clips for damage or corrosion. Make sure the cables and clips are firmly connected.
There are two batteries each (total: 4) on both sides at the rear of the machine. If the battery capacity of the operating machine
is smaller than the battery capacity of the non-operating machine, use two additional operating machines. Connect the booster
cable from one machine to the battery on the right side of the non-operating machine battery, connect the booster cable from
the other machine to the battery on the left side of the non-operating machine using the same procedure.
Connecting the Booster Cables
Keep the ignition switch in the OFF position. Connect the booster cable as
follows, in the order of the numbers marked.
1. Make sure that the ignition switches on the operating machine and the
non-operating machine are both in the OFF position.
2. Connect one clip of the booster cable (A) and (B) to the positive
terminal of the non-operating machine.
3. Connect the other clip of booster cable (A) and (B) to the positive
terminal of the operating machine.
4. Connect one clip of booster cable (C) to the engine block on the nonoperating machine away from the battery.
5. Connect the clip of booster cable (C) to the engine block away from the non-operating machine.
Starting the Engine
• Make sure the clips are firmly connected to the battery terminals.
• Turn the ignition switch on the non-operating machine to the START position and start the engine. If the engine does not
start, wait for 2 minutes before trying again.
WA900-3LC 2-117
OPERATION
Disconnecting the Booster Cables
After the engine has started, disconnect the booster cables in the reverse
order in which they were connected.
1. Remove one clip of booster cable (C) from the engine block on the
non-operating machine.
2. Remove the other clip of booster cable (C) from the negative terminal
on the operating machine.
3. Remove one clip of booster cable (A) and (B) from the positive
terminal on the operating machine.
4. Remove the other clip of booster cable (A) and (B) from the positive
terminal on the problem machine.
2-118 WA900-3LC
OPERATION
TROUBLESHOOTING TABLE
• (Always contact your distributor when dealing with these items).
• In cases of abnormalities or causes which are not listed below, contact your distributor for repairs
ELECTRICAL SYSTEM.
Problem Main Causes Remedy
Lamp does not glow brightly even when the • Defective wiring • (Check, or repair loose terminals)
engine runs at high speed • Improperly adjusted alternator belt • Adjust alternator belt tension, for details,
see “EVERY 250 HOURS OF SERVICE”
Lamps flickers while engine is running on page 3-56.
Charge indicator does not go out even when • Defective alternator • (Replace or rebuild)
engine is running • Defective wiring • (Check, repair)
Abnormal noise coming from alternator • Defective alternator bearings • (Replace or rebuild)
Starter motor does not operate when ignition • Defective wiring • (Check, repair)
switch is turned to ON • Insufficient battery charge • Charge
Starter solenoid is ratcheting • Insufficient battery charge • Charge
• Insufficient battery charge • Charge

Starter motor turns engine slowly
• Defective starter motor • (Replace or rebuild)
Starter motor drive disengages before engine • Defective wiring • (Check, repair)
starts • Insufficient battery charge • (Charge)
• Defective heater relay • (Replace)

Preheating monitor does not light • Defective wiring • (Check, repair)
• Defective monitor pilot lamp • (Replace)
Engine oil pressure monitor lamp does not

• Defective monitor • (Replace)
illuminate when engine is stopped, ignition
• Defective wiring, defective sensor • (Check, repair, replace)
switch in the ON position
Battery charge monitor lamp does not light up

• Defective wiring • (Check, repair)
when engine is stopped, ignition switch in the
• Defective monitor • (Replace)
ON position
• Disconnection in electrical heater • (Check, repair)

Outside surface of electrical heater is cold when
• Defective heater relay • (Replace)
touched
• Defective wiring or switch • (Replace)
WA900-3LC 2-119
OPERATION
CHASSIS
• Shift lever properly

• Directional lever not shift properly
Engine is running but machine does • Add oil to specified level. See “WHEN
• Lack of oil in transmission
not move REQUIRED” on page 3-24.
• Parking brake is applied
• Release parking brake
Even when engine is at full throttle, • Lack of oil in transmission • Add oil to specified level. See “WHEN
Transmission
machine moves slowly and lacks • Transmission filter is clogged REQUIRED” on page 3-24.
power • (Disassemble, clean)
• Too much oil or too little oil • Add or drain oil to specified level. See “WHEN
• Machine is not traveling in correct speed REQUIRED” on page 3-24.
Oil overheats range • Place in correct speed range
• Torque converter stalled for long periods • Reduce stall time
• Engine is overheating • (Check engine)
• Lack of oil • Add oil to specified level. See “WHEN

Noise generated
REQUIRED” on page 3-24.
• Lack of oil • Add oil to specified level. See “WHEN

Axle
Noise generated
REQUIRED” on page 3-24.
• Disc has reached wear limit • (Replace disc)

• Defective hydraulic system • Add oil to specified level. See “CHECKS
Brake has no effect even when ★ Lack of oil BEFORE STARTING YOUR WORK CYCLE”
pedal is depressed • Air in brake system on page 2-71.
Disk brake
• Bleed air. See “WHEN REQUIRED” on page 3-

24.
• Exhaust hole in treadle valve clogged • Clean

Brake drags or remains applied • Power cluster breather clogged • Clean
• Defective operation of slack adjuster • (Check, repair)
Brakes slip • Worn disc • (Replace)

Park brake
• Linkage is loose • Adjust

• Pad is wet • Clean
Braking effect is poor
• Deteriorated air cylinder spring • (Replace spring)
• Worn pad • Adjust or replace
Steering
• Steering gear adjustment is too tight • (Adjust)

Steering wheel steers heavy
• Linkage is stiff • (Check linkage, replace if necessary)
• Add oil to specified level. See “EVERY 100

Lack of lifting power for bucket. • Lack of oil HOURS OF SERVICE” on page 3-52.
Bucket takes time to rise (slow) • Clogged hydraulic tank filter • Replace filter. See “EVERY 2000 HOURS OF
SERVICE” on page 3-76.
• Replace with good quality oil.

Hydraulic System
• Incorrect oil being used • Add oil to specified level. See“EVERY 100
Excessive bubbles in oil • Oil level is low HOURS OF SERVICE” on page 3-52.
• Air in oil line • Bleed air. See “WHEN REQUIRED” on page 3-
24.

HOURS OF SERVICE” on page 3-52.
Hydraulic pressure is low • Oil level is low, pump sucking air
• Bleed air. See “WHEN REQUIRED” on page 3-
24.

• Oil level is low
Movement of cylinder is irregular HOURS OF SERVICE” on page 3-51.
• Oil leakage inside the cylinder
• (Repair)
2-120 WA900-3LC
OPERATION
ENGINE
• Engine oil pan oil level is low (sucking in • Add oil to specified level, see “CHECKS
air) BEFORE STARTING YOUR WORK CYCLE”
• Clogged oil filter cartridge on page 2-71.
Engine oil pressure monitor lights up
• Defective tightening of oil piping joint, oil • Replace cartridge, see “EVERY 250 HOURS OF
leakage from damaged part SERVICE” on page 3-56.
• Defective engine oil pressure sensor • (Check, repair) (Replace sensor)
• Add coolant, repair, see “CHECKS BEFORE

• Coolant level low, leakage STARTING YOUR WORK CYCLE” on page 2-
• Loosen fan belt 71.
• Dirt or scale accumulated in cooling • Adjust fan belt tension, see “WHEN REQUIRED”
system on page 3-24.
Steam is emitted from top part of radiator
• Clogged radiator fins or damaged fins • Change coolant, clean inside of cooling system,
(pressure valve)
• Defective thermostat see “WHEN REQUIRED” on page 3-24.
• Loose radiator filler cap (high altitude • Clean or repair, see “WHEN REQUIRED” on
operation) page 3-24.
• Defective water level sensor • (Replace thermostat) (Replace sensor)
• Tighten cap or replace packing.
• Defective fuel injection pump or nozzle • (Replace pump or nozzle)

• Starter motor cranks engine sluggishly • See “ELECTRICAL SYSTEM.” on page 2-119.
• Lack of fuel • Add fuel, see “CHECKS BEFORE OPERATING
Engine does not start when starter motor
• Air in fuel system THE MACHINE” on page 2-69.
is engaged
• Preheating monitor does not light up • Repair place where air is sucked in, see “EVERY
• Defective compression 500 HOURS OF SERVICE” on page 3-59.
• Defective valve clearance • (Adjust valve clearance).
• Add oil to specified level

• Too much oil in oil pan • Change to specified fuel “CHECKS BEFORE
Exhaust gas is white or blue
• Improper fuel STARTING YOUR WORK CYCLE” on page 2-
71.
• (Replace nozzle)
• Defective injector nozzle
• Clean or replace, see “WHEN REQUIRED” on
• Clogged air cleaner element
Exhaust gas occasionally turns black page 3-24.
• Poor compression
• (See defective compression above)
• Defective turbocharger
• (Clean or replace turbocharger)
• Low grade fuel being used • Change to specified fuel

Abnormal noise generated, combustion • Overheating • Refer to coolant temperature monitor lights
or mechanical • Damage muffler (Replace muffler)
• Excessive valve clearance • (Adjust valve clearance)
WA900-3LC 2-121
OPERATION
MEMORANDUM
2-122 WA900-3LC
3MAINTENANCE
WA900-3LC 3-1
MAINTENANCE
GUIDES TO MAINTENANCE
It is important to follow all maintenance procedures listed in this manual.
Perform all maintenance and repair work on hard, flat, level ground.
Follow all warning, safety, and repair procedures as outlined in this
manual.
Set the machine in the inspection and maintenance position shown to the
right.
Lower the work equipment to the ground and block the front and rear tires.
When performing any repairs or maintenance on the machine, OSHA law

requires those personnel who perform the repairs or maintenance to LOCK
and TAG the machine for safety purposes.
Set all control levers to the neutral or HOLD position.
Set the safety levers in the LOCK position.
Press the parking brake switch to apply the parking brake.
Lock the front and rear frames with the safety bar.
3-2 WA900-3LC
MAINTENANCE
Check Service Hour Meter:
Check the service hour meter reading every day to see if it is time for any necessary maintenance to be carried out.
KOMATSU MINING SYSTEMS genuine replacement parts:

Use genuine KOMATSU MINING SYSTEMS parts specified in the Parts Book as replacement parts.
KOMATSU MINING SYSTEMS genuine oils:

Use genuine KOMATSU MINING SYSTEMS oils and grease. Choose oils and grease with proper viscosities specified
for ambient temperature.
Always Use Clean Washer Fluid:
Use automobile window washer fluid. Never use alcohol or other flammable fluids as washer fluid.
Always Use Clean Oil And Grease:
Use clean oil and grease. Keep containers clean. Keep foreign materials away from oil and grease. Never mix lubricants.
Keeping The Machine Clean:
Always keep the machine clean. This makes it easier to find problems. In particular keep grease fittings, breather vents and oil
level gauges. After disconnecting any electrical connector, cover the connector with a plastic bag to prevent oil or dust from
contact surfaces.
Be Careful Of Hot Water And Oil:
Draining hot oils and coolants or removing filters immediately after the engine stops can be hazardous. Allow the engine to
cool. If the oil has to be drained, warm up the engine to a suitable temperature, 20 to 40° C (68 to 104° F) before draining oil.
Check For Foreign Materials In Drained Oil And On Filter:
After oil is changed or filters are replaced, check the oil and filters for metallic particles and foreign materials. If large
quantities of metallic particles or foreign materials are found, consult your distributor immediately.
Fuel Filler Strainer:
If your machine is equipped with a fuel filler strainer, do not remove it while fueling.
Oil Change:
Check or change oils in the places where dust or foreign materials cannot get in the oils.
Warning Tag:
Attach the warning tag [09963-03000] to the start switch or other appropriate control
levers to alert personnel of the circumstances when working on the machine. The warning
tag is supplied together with the tools.
WA900-3LC 3-3
MAINTENANCE
Obey Precautions:
During machine operation, always observe the precautions on the safety label attached to the machine.
Welding On Machine:
• Turn off the engine ignition switch.

• Disconnect the batteries.
• Disconnect engine ECM harness at engine interface connection.
• Do not apply more than 200 V continuously.
• Connect the grounding cable within 1 m (1 ft) from the area to be welded.
• Stay clear from seals or bearings when welding.
• Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
• Never weld any piping or tubing containing fuel or oil.
• Always have a fire extinguisher near your work area when welding.
Fire Prevention:
Use nonflammable cleaners for cleaning parts. Keep open flames or lighted cigarette away from light oils.
Clamp And Gasket Surfaces:
When o-rings or gaskets are removed, clean the surfaces and replace the o-rings or gaskets with new. Be sure to carefully
install o-rings and gaskets when assembling.
Objects In Your Pockets:
Keep your pockets free of loose objects which can fall or drop into the machinery components.
Checking Underneath Machine:
When working in rocky areas, check for damage underneath the machine.
Precautions When Washing Machine:
• Never steam clean or spray high pressure water directly into the radiator.
• Never spray or steam clean electrical components.
• Never flood, steam clean or wash the inside of the operator’s cab with high pressure water.
Pre And Post Work Checks:
Before starting work in mud, rain, snow or on sand, check plugs and valves for tightness. Wash the machine immediately after
working to protect components from rusting. Lubricate components more frequently than usual. Be sure to lubricate work
equipment pins daily if they are submerged in water. On job sites were heavy duty operations are common, grease the machine
more frequently.
3-4 WA900-3LC
MAINTENANCE
Dusty Work Sites:
When working in a dusty work sites, do as follows:

• Inspect the air cleaner indicator lamp to see whether the air cleaner is plugged. Clean the air cleaner at shorter inter-
vals than specified.
• Clean the radiator core frequently to avoid clogging.
• Clean and replace the fuel filter frequently.
• Clean electrical components, especially the starter motor and alternator, to avoid accumulation of dust.
Avoid Mixing Oils:
Never mix oils of different brands. If the only oil you have is a different brand from the one that is used in the machine, replace
all the oil.
Greasing The Rod Ends:
Because rod ends are of the oil less type, no greasing is required, although a grease nipple is installed on the rod end lever
linkage. The rod end should be greased only when it becomes stiff after a long span of service.
Controller:
The controller for the machine monitor may be mistakenly actuated by interference from external electric waves. For this
reason, when installing a radio or other such device, consult your distributor.
OUTLINE OF SERVICE
• Use genuine KOMATSU MINING SYSTEMS parts for replacement.
• When changing or adding oil, do not use a different type of oil.
• Unless otherwise specified, the oil and coolant used at the time of shipment from the factory are as shown in the table
below.
Item Type Of Fluid
Regular Interval Extended Interval

Engine oil pan SAE 15W-40 API classification
CG4 CG4/SH
CF-4 or CF-4/SG
Transmission case SAE 30 API classification CD
Axle (Front and rear) AX0 75
Hydraulic tank SAE 10W API classification CD
Linkage Pins Lithium base grease No. 2 with 3 to 5% molybdenum
ASTM D975 No. 2

Fuel tank
(However ASTM D975 No. 1 is used for winter season)
Radiator Super Coolant (AF-ACL) 30% added to water
WA900-3LC 3-5
MAINTENANCE
OUTLINE OF OIL, FUEL, AND COOLANT USED
OIL
• Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pressure), it
deteriorates with use. Always use oils that matches the grade and temperature given in this Operation and Maintenance
Manual.
• Be careful when handling lubricants, keep your work area and equipment clean, this will help prevent any impurities
(water, metal particles, dirt, etc.) from entering the system. Take particular care not to let any impurities get in when
adding oil.
• Never mix oils of different grades or brands.
• Always maintain oil at specified levels. Never over fill or allow oil level to go below the indicator marks on the oil level
gauge. Over filling may cause oil foaming, under filling may starve vital engine components of proper lubrication.
• If the oil in the work equipment is not clear, water or air is entering the circuit. In such cases, contact your distributor.
• When changing the oil, always replace the related filters at the same time.
• It is recommended that an analysis of the oil periodically be made to check the condition of the machine. For those who
wish to use this service, contact your distributor.
FUEL
• Fuel pumps are precision instruments, fuel containing water or dirt may damage the fuel injection system.
• Be extremely careful not to let impurities enter fuel when re-fueling machine.
• Always use the fuel specified in the Operation and Maintenance Manual. Fuel may congeal depending on the temperature,
particularly in temperatures below -15° C (5° F), if necessary change to a fuel that matches the temperature where
operating machine.
• To prevent moisture from condensing inside the fuel tank, always fill the tank after completing the days work.
• Before starting the engine, drain the sediment and water from the fuel tank.
• If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.
COOLANT
• River, swamp, lake, well or tap water contains large amounts of calcium and other impurities, if used, scale will build up
in the engine and radiator. This will prevent proper heat exchange and cause overheating. When adding water use distilled
water, there are no minerals to cause scale build up. For specific requirements, see “COOLANT SPECIFICATIONS” on
page 3-12.
• When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
• This machine is shipped from the factory with antifreeze in the coolant system. This antifreeze is effective in preventing
corrosion. It can be used continuously for 2 years or 4000 hours.
• Never use alcohol, kerosene, diesel fuel or other flammable fluids as a coolant. Use only non flammable KOMATSU
MINING SYSTEMS approved coolant in the machines cooling system.
• The proportion of antifreeze to water differs according to the ambient temperature. For details on mixing proportions, see
“COOLANT SPECIFICATIONS” on page 3-12.
• If the engine overheats, wait for the engine to cool before adding coolant.
• If the coolant level is low, it will cause overheating and corrosion from air in the cooling system.
GREASE
• Grease is used to reduce friction and help prevent wear.
• Grease fittings not referred to in the maintenance schedule do not require any scheduled greasing. Add grease to these
areas only if something becomes stiff or squeaky.
• Always wipe off all of the old grease that is pushed out when greasing.
3-6 WA900-3LC
MAINTENANCE
STORING OIL AND FUEL
• Keep indoors to prevent any water, dirt, or other impurities from entering storage containers. When keeping drums for a
long periods, lay the drum on its side so the filler port on the drum is at the side, to prevent moisture from being sucked in.
Periodically inspect drums for leakage. If drums have to be stored outside, cover them with a waterproof cover or take
other measures to protect them. To prevent any change in quality during long term storage, be sure to use in the order of
first in - first out (use the oldest oil or fuel first).
FILTERS
Filters are extremely important parts. They prevent impurities in the fluids and air circuits from entering equipment and
causing problems. Replace all filters periodically.
For details, see “MAINTENANCE SCHEDULE CHART” on page 3-20. However, when working under severe conditions,
it is necessary to consider replacing the filters at shorter intervals according to the oil and fuel (sulfur content) being used.
• Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
• When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, contact
your distributor.
• Do not open packs of spare filters until they are to be used.
• Always use genuine KOMATSU MINING SYSTEMS filters.
ELECTRIC SYSTEM
• If the wiring gets wet or the insulation becomes damaged, a malfunction of the machine may occur.
• Services relating to the electric system are (1) check of fan belt tension, (2) check of damage or wear in the fan belt and
(3) check of battery fluid level.
• Never remove or disassemble any electric components installed in the machine.
• Never install any electric components other than those specified by KOMATSU MINING SYSTEMS.
• When working in a corrosive environment, carefully clean the electric system to prevent corrosion.
• When installing a cab cooler or any other electrical equipment, connect it to an independent power source. The optional
power source must never be connected to the fuse, starting switch, or battery relay.
WA900-3LC 3-7
MAINTENANCE
PARTS WEAR LIST
Parts such as the filter elements, bucket teeth, etc. are to be replaced at the time of periodic maintenance or before their
abrasion limits are reached. The wear parts should be changed correctly in order to use the machine economically. For a part
change, only genuine KOMATSU MINING SYSTEMS parts should be used. When ordering parts, check the part number in
the parts book. Use the current parts book and numbers.
( ): The items in parentheses are to be replaced at the same time.
Item Part No. Part Name Qty. Replacement Frequency
Engine oil filter Cartridge 4 Every 500 hours of service
Engine oil by pass filter Cartridge 2 Every 500 hours of service
Fuel filter Cartridge 2 Every 500 hours of service
Element 6
Transmission oil filter (O-ring) (12) Every 500 hours of service
(O-ring) (6)
Corrosion resister Cartridge 2 Every 1000 hours of service
Element
3
Hydraulic oil filter (O-ring) Every 2000 hours of service
(3)
Element 3
Hydraulic tank breather Every 2000 hours of service
(O-ring) (6)
Outer Element 2
Air cleaner ---
Inner Element 2
Air conditioner air filter Element 2 ---
Tooth 10
(Pin) (10)
Left lip protector 4
(Pin) (8)
Right lip protector 4
Bucket wear items (Pin) (8) ---
Center lip protector 1
(Pin) (2)
Corner end cap 2
Vertical shrouds 2
(Pin) (4)
3-8 WA900-3LC
MAINTENANCE
FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE CHART
SELECTION OF FUEL, COOLANT AND LUBRICANTS
It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the
quality of the fuel, coolant and lubricant must remain with the supplier. When in doubt, consult your distributor. The specified
fuel, coolant and lubricants recommended for this machine are as shown in the following table.
✰ Use a multi purpose type grease containing 3 to 5% molybdenum. This will provide maximum service life.
✰✰ ASTM D975 No. 1
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.
ASTM: American Society of Testing and Materials SAE: Society of Automotive Engineers
NLGI: National Lubricating Grease Institute API: American Petroleum Institute
When operating this machine at temperatures below -20°C (-4°F) other equipment is needed, consult your distributor.
WA900-3LC 3-9
MAINTENANCE
ENGINE OIL SPECIFICATIONS
NORMAL OPERATION
Oil performance recommendations are as follows:
• The use of a quality engine oil combined with appropriate oil and filter change intervals are critical factors in maintaining
engine performance and durability.
• KOMATSU MINING SYSTEMS Engine Oil or multi-viscosity engine oil meeting American Petroleum Institute (API)
performance classification CF-4, CG-4, CF-4/SG or CG-4/SH or MIL-L-2104D or E is recommended.
Remark
Classification CD, CE, CD/SF or CE/SF oils may be used in areas where CF-4, CG-4, CF-4/SG or CG-4/SH oil
is not yet available. If API classification CC or CC/CD is used, reduce the engine oil change interval by half.
• A sulfated ash limit of 1.0 to 1.5 mass percent is suggested for optimum valve and piston deposit and oil consumption
control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed
on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage
and lead to excessive oil consumption.
• The API service symbol displays the following information. The upper half of the symbol displays the appropriate oil
categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the
SAE oil viscosity grade.
Oil viscosity recommendations are as follows:
• The use of a multi-grade lubricating oil has been found to improve oil consumption control and improve engine cranking
in cold temperatures while maintaining lubrication at high operating temperatures.
• While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previous table for oil
viscosity recommendations for extreme climates.
Remark
Limited use of low viscosity oils, such as SAE 10W-30, may be used for easier starting and provide sufficient
oil flow at ambient temperatures below -5° C (+23° F). However, continuous use of low viscosity oils can
decrease engine life due to wear.
• Special break in lubricating oils are not recommended for a new or rebuilt engine. Use the same type of oil during the
break in as specified for normal operation.
Additional information regarding lubricating oil availability throughout the world is available in the EMA Lubricating Oils
Data Book for Automotive and Industrial Engines. The data book may be ordered from the Engine Manufacturers Association,
401 North Michigan Ave., Chicago, Il U.S.A. 60611. The telephone number is (312) 644-6610.
ARCTIC OPERATION
If an engine is operated consistently in ambient temperatures below -23° C (-10° F) and there are no provisions to keep the
engine warm when it is not in operation, use a synthetic engine oil API performance classification CF-4, CG-4, CF-4/SG or
CG-4/SH with adequate low temperature properties such as SAE 5W-20 or 5W-30. The oil supplier must be responsible for
meeting the performance service specifications.
Remark
The use of a synthetic base oil does not justify the extended oil change intervals. Extended oil change intervals
can decrease engine life due to factors such as corrosion, deposits, and wear.
3-10 WA900-3LC
MAINTENANCE
TRANSMISSION, CONVERTER, TRANSFER CASE, COOLER, SERVICE
BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS
KOMATSU MINING SYSTEMS Engine Oil or engine oil meeting American Petroleum Institute (API) performance
classification CF-4, CG-4, CF-4/SG or CG-4/SH or MIL-L-2104D or E is recommended.
Remark
Classification CD, CE, CD/SF or CE/SF oils may be used in areas where CF-4, CG-4, CF-4/SG or CG-4/SH oil
is not yet available.
DRIVE AXLE OIL SPECIFICATIONS
For Drive Axle Oil, Use Only The 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
Engine oil SAE 30W API classification CD or CE can be substituted for axle oil, it might increase in brake noise, but it will
not affect durability.
DIESEL FUEL SPECIFICATIONS
Never mix gasoline, gasohol and/or alcohol with diesel fuel. This practice creates an extreme fire hazard
and under certain conditions an explosion could result in personal injury or death. Never remove the fuel
tank filler cap or refill the fuel tank while the engine is running, hot or when the machine is indoors. Fumes
are dangerous, as a spark or flame could result in a fire or explosion.
Remark
Due to the precise tolerances of diesel fuel injection systems, it is extremely important the fuel be kept clean
and free of contaminates or water. Contaminates or water in the system can cause severe damage to both the
injection pump and nozzles.
Remark
Below -12° C (+10° F) the paraffin in ASTM Grade No. 2-D diesel fuel will change to wax particles and clog the
fuel filters. For best results use Grade No. 1-D diesel fuel in cold weather.
For normal service above -10° C (+14° F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40
is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions.
Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent
misfires and excessive smoke. At operating temperatures below -10° C (+14° F) or extended engine idle, use ASTM Grade
No. 1-D diesel fuel. The use of lighter fuels can reduce fuel economy. Where a winterized blend of Grade No. 2-D and
No. 1-D fuels is available, it may be substituted for Grade No. 1-D fuel. It is the suppliers responsibility to provide the fuel for
the anticipated ambient temperature. Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the
lowest expected fuel temperature. Cloud point is the temperature at which crystals begin to form in the fuel. The viscosity of
the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication. Optionally, the equivalent grades of
recognized Federal Government specifications may be used; the latest revisions of VV-F-800a.
WA900-3LC 3-11
MAINTENANCE
COOLANT SPECIFICATIONS
GENERAL
Selection and maintenance of the engine coolant is important to long engine life. The following information provides
recommendations for selecting the engine coolant and maintaining the supplemental coolant additives (SCA).
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives.
Supplemental coolant additive recommendations are included in the section entitled, see “SUPPLEMENTAL COOLANT
ADDITIVES” on page 3-13. The coolant mixture must be drained and replaced at the specified service interval shown; see
“MAINTENANCE SCHEDULE CHART” on page 3-20 or every two years of operation, whichever comes first.
WATER
Use water with a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited water must meet
the following standards:
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water
containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified
amount will cause scale deposits to develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale
deposits, corrosion or a combination of these.
If any of the above requirements cannot be met, use distilled, deionized, or demineralized water. To determine if local water
supplies meet these standards, samples can be tested by water treatment laboratories. Softened water that is prepared using
common salt (sodium chloride) contains excessive amounts of chlorides and should not be used.
Remark
Never use water alone in the cooling system, rust, scale deposits and corrosion will occur.
ANTIFREEZE
In climates where the temperature is above -34° C (-30° F), use a coolant mixture that contains 50 % antifreeze. Antifreeze is
essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its
boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is required. Never
use more than 68 % antifreeze under any condition. An antifreeze concentration greater than 68% will adversely affect freeze
protection and heat transfer rates. Antifreeze concentrations between 68% and 100% actually have a higher freezing point than
a 68% antifreeze concentration and should not be used due to reduced heat transfer rates.
Ethylene glycol, low silicate antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali
metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica gel (hydro gel). This gel formation can
occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive.
Do not use methanol or alcohol as an antifreeze because of its low boiling point.
Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain
corrosion protection. Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.
Remark
Do not mix antifreeze solutions. Mixed solutions make it impossible to determine the protection against
freezing. Antifreeze containing sealer or anti leak additives should not be used in this system. Sealer or
anti-leak additives will clog the cooling system and cause overheating.
3-12 WA900-3LC
MAINTENANCE
Use extreme caution when adding coolant to a hot radiator to avoid being burned. Wear gloves and face
shield and keep face and any exposed body parts away from the radiator filler neck.
Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection
against freezing. An antifreeze concentration greater than 68% will adversely affect antifreeze protection and heat transfer
rates. Antifreeze concentrations between 68% and 100% actually have a higher freezing point than a 68% antifreeze
concentration and should not be used due to reduced heat transfer rates.
Remark
Do not use a 100% antifreeze solution for freeze protection, this will cause severe corrosion in the cooling
system and if not detected will cause radiator and oil cooler core damage. Use a water/antifreeze solution as
described in the following table.
The following table shows the approximate percentage of antifreeze solution required for various temperatures.
Percentage% of Antifreeze
Approximate Freezing Point Specific Gravity at 16°C (60°F)
Concentration by Volume
0°C (+32°F) 0 1.000

-7°C (+20°F) 15 1.025
-12°C (+10°F) 25 1.040
-18°C (0°F) 33 1.053
-23°C (-10°F) 40 1.062
-29°C (-20°F) 45 1.070
-34°C (-30°F) 48 1.074
-40°C (-40°F) 53 1.080
-46°C (-50°F) 56 1.083
-51°C (-60°F) 59 1.088
-57°C (-70°F) 62 1.092
-62°C (-80°F) 65 1.095
-68°C (-90°F) 67 1.097
-69°C (-92°F) 68 1.098
In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor or supplemental coolant additive
(SCA), to protect the engine cooling system.
SUPPLEMENTAL COOLANT ADDITIVES

1. All supplemental cooling system additives, including those in antifreeze solutions, become depleted through normal
operation. If the coolant additives in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and
attacks and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners
which contain these additives must be added to maintain corrosion protection.
2. Soluble oil is not recommended for use in this engine as its use will reduce heat transfer and allow internal engine
damage. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still
the best coolant. A corrosion inhibitor/conditioner is recommended to inhibit corrosion in the cooling system for the
following reasons:
WA900-3LC 3-13
MAINTENANCE
• Improved compatibility with high silicate antifreezes to minimize hydro gel formation if over concentration occurs.
• Provides engine protection in the following areas:
Solder bloom/corrosion Cylinder liner cavitation corrosion
Copper corrosion/stress cracking/erosion Aluminum cavitation corrosion
Oil or additive plugging Seal and gasket degradation
Maintenance of Supplemental Coolant Additives
Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and corrosion.
New machines are delivered with antifreeze protection. Service at a regular scheduled interval specified in MAINTENANCE
SCHEDULE CHART on page 3-22★ with a replacement coolant filter.
Each time the coolant is drained and replaced, the coolant must be recharged with supplemental coolant additives. New
coolant can be correctly charged with coolant additives by using a replacement coolant filter and/or concentrate.
If coolant is added between drain intervals, additional coolant additives may be required.
Coolant Testing for Conditioner Concentration
When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The SCA
concentration must not fall below 1.0 unit per 3.8 liter (1 gal) or exceed 2 units per 3.8 liter (1 gal) of coolant. The only
accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis. For
this reason, the coolant inhibitor should be maintained as shown in MAINTENANCE SCHEDULE CHART on page 3-22★
Remark
Inadequate concentration of the coolant additive can result in major corrosive damage to cooling system
components. Over concentration can cause formation of gel that can plug passages and cause overheating.
Replenishing Coolant Conditioner
Install a precharge coolant filter when the coolant is changed or a significant (more than 50%) coolant loss occurs. Install a
service coolant filter as specified in MAINTENANCE SCHEDULE CHART on page 3-22★. When antifreeze is added,
add coolant conditioner equal to 1.0 unit per 3.8 liter (1 US gal) of antifreeze.
Remark
Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no
test kit available to measure concentration levels with mixed chemical solutions.
Supplemental Coolant Additive Maintenance Guide
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze
alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion protection
must be supplied through periodic additions of supplemental coolant additives to the coolant.
To protect against corrosion, a new coolant charge must be brought up to 0.26 SCA unit per liter [one unit per U.S. gallon] of
coolant (initial charge). Maintain the correct SCA concentration by changing the service coolant filter at each engine oil and
filter change interval.
Each time the coolant is drained or replace, the coolant must be recharged with supplemental coolant additives. Use the
appropriate replacement coolant filter listed in following tables. The coolant mixture must be drained and replaced as defined
under General.
3-14 WA900-3LC
MAINTENANCE
The amount of a replacement inhibitor is determined by the length of the service interval and the cooling system capacity.
Refer to the DCA4 Unit Guide for the selection of the correct filter to replenish the SCA.
If coolant is added between drain intervals, additional SCA will be required. Check the coolant DCA concentration level
anytime make up coolant is added to the system. The SCA concentration must not fall below 0.13 units per liter or exceed 0.5
units per liter [0.5 units per U.S. gallon or exceed 2 units per U.S. gallon].
DCA4 UNIT GUIDE
Fleetguard® Part No. DCA4 Units
DCA4 Coolant Filter

2
WF-2070
4
WF-2071
6
WF-2072
8
WF-2073
12
WF-2074
15
WF-2075
23
WF-2076
0
WF-2077
DCA4 Liquid
DCA60L 4 (1 pt)
DCA80L 1760 (55 gal)
DCA4 Powder
DCA95 20
DCA4 Precharge and Service Filters
Service Filter
System Capacity Precharge Filter (See Remark 1)
(See Remark 3)
Liters Gallons
19 to 26 5 to 7 WF-2072 WF-2070
30 to 38 8 to 10 WF-2073 WF-2071
42 to 57 11 to 15 WF-2074 WF-2071
61 to 76 16 to 20 WF-2075 WF-2071
80 to 114 21 to 30 WF-2076 WF-2072
118 to 190 31 to 50 (See Remark 2) WF-2073
Remark 1
After draining and replacing the coolant, always precharge the cooling system to maintain the SCA
concentration between 1.0 and 2.0 units per 3.8 liter (1 US gal).
When performing service which requires draining the cooling system, discard the coolant. Reusing coolant can introduce
contaminates or over concentrated chemicals, resulting in premature failure of the systems components.
Remark 2
To precharge cooling systems larger than 114 liter (30 gal) do the following:
• Install appropriate service filter listed in the above table based on cooling system capacity.
Example: 95 gal (360 liter) cooling system capacity

-15 Units (1) WF-2075 Filter
80 Units
WA900-3LC 3-15
MAINTENANCE
The answer represents the additional units required to precharge the cooling system. Four bottles of powder, part number
DCA95, will provide a sufficient amount of SCA units (80) to precharge the example cooling system.
Install the appropriate service filter at the next and subsequent maintenance intervals.
Remark 3
Change the coolant filter at every engine oil and filter change interval to protect the cooling system.
Maintain a nominal SCA concentration of 1.0 unit per 3.8 liter (1 US gal) of coolant in the system. Less than 0.5 units per
3.8 liter (1 US gal) indicates an under concentrated coolant solution. More than 2.0 units per 3.8 liter (1 US gal) indicates an
over concentrated coolant solution.
To check the SCA concentration level, use coolant test kit, CC-2626. Instructions are included with the test kit.
SCA Unit Concentration Guide
Number of Solution (A) Drops to

Coolant Condition Action Required
Cause Color Change
Extremely under concentrated less than 0.4 Initially charge the system to a minimum of
0 to 10 Drops
SCA units per 3.8 liter (1 US gal) 1.0 SCA unit per 3.8 liter (1US gal).
Add SCA liquid units to maintain 1.0 SCA

Marginally under concentrated - 0.4 to 0.8
11 to 16 Drops unit per 3.8 liter (1 US gal) minimum or
SCA units per 3.8 liter (1 US gal)
change the DCA 4 coolant filter.
Acceptable - 0.85 to 1.3 SCA units per

17 to 25 Drops None.
3.8 liter (1 US gal)
Highly acceptable - 1.35 to 2.0 SCA units

26 to 35 Drops None.
per 3.8 liter (1 US gal)
Marginally over concentrated - 2.1 to 3.3

36 to 55 Drops Review maintenance practice.
SCA units per 3.8 liter (1 US gal)
Drain 50% of the coolant and replace with

Over 55 Drops Extremely over concentrated water antifreeze mixture. Retest the system
for correct SCA unit concentration.
Cooling System Test Kit
The following cooling system test kit may be purchased from your
KOMATSU MINING SYSTEMS distributor.
This Fleetguard® coolant test kit, part number CC-2626 is used to check
the concentration of coolant additives in the cooling system.
(1). Test strip bottles

(2). Solution #1 bottle
(3). Small plastic container
(4). Large plastic cup
(5). Syringe
3-16 WA900-3LC
MAINTENANCE
STANDARD TIGHTENING TORQUES FOR FASTNERS
NECESSARY MAINTENANCE TOOLS
No. Name of tool Part No. Remarks
.09002-
Open end wrench set:
01317.09000-
1. 8 x 10 mm wrench
30006.09002-
2. 12 x 14 mm wrench
00810.09002-
1 Open end wrench set 3. 13 x 17 mm wrench
01214.09002-
01922.09002-
02427.09002-
03032
.09021-
Socket set and box:
03044.09020-
1. 10 mm socket - 13 mm drive
10284.09021-
01016.09021-
01319.09021-
01422.09021-
01725.09021-
01928.09021-
02233.09021-
02436.09021-
2 Socket wrench set and box 9. 30 mm socket - 19 mm drive
02739.09021-
03246.09021-
03653.09022-
12. 150 mm extension - 13 mm drive
00150.09022-
13. 250 mm extension - 19 mm drive
00250.09023-
14. 13 mm drive breaker bar
00300.09024-
15. 19 mm drive L breaker bar
00300.09025-
16. 13 mm drive universal joint
00075.09026-
17. 13 mm ratchet wrench
00250.09027-
18. Breaker bar extension
00300
3 Screwdriver 09033-00190 Cross head/flat head interchangeable type
4 Adjustable wrench 09014-10200 0 to 24 mm jaw opening
5 Adjustable pliers 09036-00150 Two position
6 Wrench 09001-03600 36 mm jaw
7 Filter wrench 09019-08035 For filter change
8 Bar 424-98-11130 Extension bar
9 Tire gauge 09289-10000 (must be calibrated)
10 Thickness gauge 09054-00009 (must be calibrated)
11 Grease pump 07952-80003 For greasing work
12 Nozzle 07951-31400 Hose nozzle for grease pump
13 Grease cartridge 07950-90403 Lithium based grease - 400 g
14 Nipple 424-98-11110 For transmission oil drain
15 Hose, drain 424-98-11120 For external drain valves
16 Hammer, ball peen 09039-00150 General usage
17 Plate 09963-03000 Warning tag
WA900-3LC 3-17
MAINTENANCE
TORQUE LIST
Unless otherwise specified, tighten the metric bolts and nuts to the torques
shown in the table.
The tightening torque is determined by the width across the flats (B) of the
nut and bolt.
If it is necessary to replace any nut or bolt, always use a KOMATSU

MINING SYSTEMS genuine part of the same size as the part that was
replaced.
All torque values are listed as a lubricated torque. Never dry torque a
faster, torque values may vary.
1 Nm = 0.74 lbf ft
Thread diameter of bolt (mm) Width across flat (mm)

(A) (B)
Nm lbf ft
6 10 13.2 ± 1.4 9.73 ± 1.03

8 13 31.4 ± 2.9 23.2 ± 2.1
10 17 65.7 ± 6.8 48.5 ± 5.0
12 19 112 ± 9.8 82.6 ± 7.2
14 22 177 ± 19 131 ± 14
16 24 279 ± 29 206 ± 21
18 27 383 ± 39 282 ± 29
20 30 549 ± 58 405 ± 43
22 32 745 ± 78 549 ± 58
24 36 927 ± 98 684 ± 72
27 41 1320 ± 140 973 ± 100

30 46 1720 ± 190 1270 ± 140
33 50 2210 ± 240 1630 ± 180
36 55 2750 ± 290 2030 ± 210
39 60 3280 ± 340 2420 ± 250
Remark
When tightening panels or parts having fixtures made of plastic or soft metals, be careful not to use excessive
tightening torque: doing so will damage the plastic or soft metal part.
PERIODIC REPLACEMENT OF SAFETY RELATED PARTS

To ensure safety at all times when operating the machine, the user of the machine must always perform periodic maintenance.
In addition, to further improve safety, the user should also perform periodic replacement of the parts listed in the table below.
These parts are particularly connected to safety and fire prevention. With these parts, material changes as time passes, or they
may easily wear or deteriorate. In either case, it is difficult to judge the condition of the parts simply by periodic maintenance
or inspections. However, if these parts show any abnormality before the replacement interval has passed, they should be
repaired or replaced immediately. If the hose clamps show any deterioration, such as deformation or cracking, replace the
clamps at the same time as the hoses. When replacing the hoses, always replace the o-rings, gaskets, and other such parts at the
same time. Ask your distributor to replace the safety critical parts.
3-18 WA900-3LC
MAINTENANCE
CRITICAL PARTS
No. Safety Critical Parts For Periodic Replacement Qty. Replacement Intervals
1 Steering hose 4
2 Hose of main suction tube 1
3 Outlet hose of steering pump 2
4 Suction hose of loader and steering pump 2
5 Outlet hose of loader pump 2
6 Suction hoses of switch pump 2
7 Outlet hoses of switch pump 2
8 Brake hose - pump to accumulator charge valve 2
9 Brake hose - accumulator to left tandem valve 4
10 Brake hose - accumulator to right tandem valve 4
11 Brake hose - charge valve to accumulator 4
12 Brake hose - right tandem valve to front brake 6
13 Brake hose - left tandem valve to rear brake 4
14 Brake hose - left tandem valve to right tandem valve 6
15 Brake hose - right tandem valve to drain block 1

Every 2 years or 4000 hours,
16 Brake hose - left tandem valve to drain block 1
whichever comes first.
17 Brake hose - drain block to hydraulic tank 1
18 Brake hose - accumulator to parking solenoid valve 2
19 Brake hose - parking solenoid valve to parking brake cylinder 2
20 Brake hose - parking solenoid valve to brake tank 1
21 Brake hose - charge valve drain to brake tank 2
22 Brake hose - brake tank to brake pump 2
23 Brake hose - charge valve PP port to accumulator 1
24 Steering cylinder seals 18
25 Treadle valve seals 10
26 Parking brake cylinder seals 10
27 Slack adjuster seals 12
28 Fuel hose, strainer to right injection pump 1
29 Fuel hose, fuel tank to strainer 1
30 Fuel hose, right injection pump to fuel tank 1
31 Turbocharger lubrication hose 2
32 Seat belt 1 Replace every 3 years
WA900-3LC 3-19
MAINTENANCE
MAINTENANCE SCHEDULE CHART
SCHEDULED MAINTENANCE CHART
SERVICE ITEM
INITIAL 50 HOURS OF SERVICE PAGE
1. Every 50 hours lubricate linkage pins 3-23
INITIAL 250 HOURS OF SERVICE PAGE
1. Replace fuel filter cartridge 3-23
2. Replace transmission oil filter element 3-23
3. Check engine valve clearance, adjust 3-23
WHEN REQUIRED PAGE
1. Check, clean and replace air cleaner element 3-24
2. Cleaning cooling system 3-26
3. Checking transmission oil level 3-28
4. Checking axle oil level 3-29
5. Cleaning axle case vent 3-30
6. Checking window washer fluid level 3-31
7. Cleaning air conditioner condenser 3-31
8. Cleaning radiator fins 3-32
9. Checking intake air heater system 3-32
10. Replacing bucket wear items 3-32
11. Lubrication 3-36
12. Checking air conditioner 3-38
13. Adjusting parking brake 3-38
14. Bleeding air from brake circuit 3-39
15. Bleeding air from PPC circuit 3-40
16. Bleeding air from hydraulic tank 3-40
17. Bleeding air from the pump 3-40
18. Replacing slow blow fuse 3-42
19. Replacing fan belt and auto tensioner 3-43
20. Selection and inspection of tires 3-43
21. Cleaning high pressure strainer 3-45
3-20 WA900-3LC
MAINTENANCE
SERVICE ITEM
CHECKS BEFORE STARTING WORK CYCLE PAGE
1. Checking monitor panel 3-46
2. Checking coolant level 3-47
3. Checking oil level in engine 3-47
4. Checking brake oil tank level 3-48
5. Checking fuel level 3-49
6. Checking electrical wiring 3-49
7. Checking tires inflation pressure 3-50
8. Checking effect of parking brake system 3-50
9. Checking effect of brakes 3-51
10. Check horn and back up alarm 3-51
11. Check lamps for dirt or damage 3-51
12. Check rear view mirror for dirt or damage 3-51
13. Check engine exhaust color and sound 3-51
14. Check operation of gauges 3-51
15. Check play and operation of steering 3-51
EVERY 50 HOURS OF SERVICE PAGE
1. Draining water and sediment from fuel tank 3-51
1. Lubrication 3-52
2. Checking oil level in hydraulic tank 3-55
3. Air conditioner fresh air filter 3-55
1. Checking battery electrolyte level 3-56
2. Checking alternator belt tension 3-56
3. Air conditioner recirculation filter 3-57
4. Checking refrigerant compressor belt 3-57
5. Checking for loose wheel hub nuts, tighten 3-58
6. Checking frame and boom 3-58
WA900-3LC 3-21
MAINTENANCE
SERVICE ITEM
1. Change engine oil and filter cartridges 3-59
2. Replacing the fuel filter cartridge 3-62
3. Replacing the transmission oil filter 3-64
4. Lubricate center drive shaft 3-66
5. Checking fan belt for wear 3-67
1. Changing transmission oil and clean strainer 3-68
2. Cleaning transmission case vent 3-70
3. Lubrication 3-71
4. Check parts of turbocharger 3-74
5. Cleaning fuel strainer 3-74
6. Checking ROPS canopy 3-74
7. Replace corrosion resistance cartridge 3-75
1. Changing hydraulic oil and filter element 3-76
2. Cleaning hydraulic tank strainer 3-80
3. Replacing hydraulic tank vent 3-81
4. Change axle oil ✰ 3-82
5. Replacing air conditioner cab filter 3-84
6. Cleaning PPC circuit strainer 3-84
7. Checking wear on brake disks 3-85
8. Checking alternator and starter motor 3-86
9. Checking engine valve clearance 3-86
10. Checking turbocharger 3-86
12. Checking accumulators 3-86
(✰) The interval of 2000 hours for changing the axle oil is for standard operations. If the brake is used frequently or the brakes make
unusual noises, change the oil at shorter intervals.
1. Checking water pump 3-87
2. Checking engine vibration damper 3-87
3. Checking fan pulley and tension pulley 3-87
3-22 WA900-3LC
MAINTENANCE
SERVICE PROCEDURE
INITIAL 50 HOURS OF SERVICE
Be sure to put a warning tag on work equipment control levers and remove
ignition key.
Carry out the following maintenance only after the initial first 50 hours.
LUBRICATION
Grease to the loader linkage every 10 operating hours or every day for the first 50 operating hours.
For details, see “WHEN REQUIRED” on page 3-24.
INITIAL 250 HOURS OF SERVICE
Be sure to put a warning tag on work equipment control levers and remove ignition key.
Carry out the following maintenance only after the initial first 250 hours.
FUEL FILTER CARTRIDGE

For details of the method of replacing, see “EVERY 500 HOURS OF SERVICE” on page 3-59.
TRANSMISSION OIL FILTER ELEMENT

For details of the method of replacing, see “EVERY 500 HOURS OF SERVICE” on page 3-59.
ENGINE VALVE CLEARANCE

For details of the method of adjustment, see “EVERY 2000 HOURS OF SERVICE” on page 3-76.
WA900-3LC 3-23
MAINTENANCE
WHEN REQUIRED
Be sure to put a warning tag on work equipment control levers and remove
ignition key.
CLEAN OR REPLACE AIR CLEANER ELEMENT
Never clean or replace the air cleaner element while the

engine is running. When using pressurized air to clean the
element, wear safety glasses or goggles to protect the eyes.
Checking
If the air cleaner caution lamp (1) on the maintenance monitor flashes,
clean the air cleaner element.
Do not clean the air cleaner element before the air cleaner pilot
lamps (right and left) flash. If the air cleaner element is cleaned
frequently before the air cleaner pilot lamps flash, the proper
performance of the air cleaner is not provided and the cleaning
efficiency is lowered. In addition, dust sticking to the cleaner element
falls on the inner element side while cleaning the element.
Cleaning or Replacing Outer Element
1. Remove wing nut (2) and cover (3), take out outer element.
2. Clean the inside of the air cleaner body.
3. Direct dry compressed air to the element from inside along its folds,
then direct it from outside along its folds and again from inside.
Remark
Never use more than 3.5 kg/cm (50 psi) of air pressure to clean
the air cleaner element. High air pressure may blow holes in air
cleaner element rendering it useless.
4. Remove one seal from the outer element whenever the outer element
has been cleaned.
5. Replace the outer element if it has been cleaned six times repeatedly or
used throughout a year. Replace the inner element at the same time.
3-24 WA900-3LC
MAINTENANCE
6. Check inner element (5) mounting nut for looseness and, if necessary,
retighten.
7. Replace seal washer (4) or nut (6) with new parts if they are broken.
• If small holes or thinner areas are found on element when it is checked with an electric
light bulb after cleaning and drying, replace the element. When cleaning the element, do
not hit it or beat it against anything. Do not use element whose folds or gasket or seal are
damaged.
8. Install the cleaned element.
Replacing Inner Element
1. First remove the outer element. Remove clip (6), nut (7) and seal washer (8) and slide
out inner element (5).
2. To prevent dust from getting in, use a clean cloth or tape to cover the air connector
(outlet side). Clean the air cleaner body interior, then remove the cover.
3. Install a new inner element to the connector and tighten it with nuts.
Do not clean and reinstall a used inner element. Install the outer
element.
The following methods require spare parts.
With Water
Spray water 3 kg/cm² (42 psi) on element from inside along folds, then
from outside and again from inside. Dry and check.
With Cleaning Agent
For removing oils and heavy dirt, the element may be cleaned in a
lukewarm solution of mild detergent, then rinsed in clean water and left
to drip dry. Never attempt to heat the element. Using warm water,
about 40°C, (140°F) instead of soapy water may also be effective.
WA900-3LC 3-25
MAINTENANCE
CLEANING COOLING SYSTEM
After the engine has been stopped, the coolant will be hot and can cause personal injury. Allow the engine
to cool before draining coolant.
Since cleaning is performed while the engine is running, it is very dangerous to go under the machine as
the machine may suddenly start moving. While the engine is running, never go under the machine.
Never remove the radiator cap when the engine is at operating temperature. At operating temperature, the
coolant is under pressure. Boiling water and steam from the radiator could cause personal injury. Allow
the engine to cool until the radiator filler cap is cool enough to touch with your hand.
Stop the machine on level ground when cleaning or changing the coolant.
Clean the inside of the cooling system, change the coolant, and replace the corrosion resistor according to the table below..
Cleaning inside of cooling system and

Type of coolant Replacing corrosion resistor
changing coolant
Permanent type antifreeze (All season Every year or every 2000 hours, whichever
type) comes first
Every 1000 hours, when cleaning the
Non-permanent type antifreeze containing Every 6 months (Drain antifreeze in spring,
inside of the cooling system or when
ethylene glycol (Winter, one season type) add antifreeze in autumn)
changing coolant.
When not using antifreeze Every 6 months or every 1000 hours,
whichever comes first
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing rate table
given below. It is actually better to estimate a temperature about 10°C (50°F) lower when deciding the mixing rate.
Mixing Rate Of Water And Antifreeze
Minimum atmospheric °C -5 - 10 - 15 - 20 - 25 - 30
temperature °F 23 14 5 -4 - 13 - 22
liter 70 91 109 124 139 150

Amount of antifreeze
gallon 18.5 24 28.8 32.8 36.7 39.7
liter 231 210 192 177 162 150

Amount of water
gallon 61 55.5 50.7 46.7 42.8 39.7
• Use distilled or non-mineral based water for the cooling water. If river
water, well water or other such water supply must be used, contact
your distributor.
• We recommend use of an antifreeze density gauge to control the
mixing proportions.
3-26 WA900-3LC
MAINTENANCE
Prepare the following:
Coolant catch container....... Min 319 liter (84 gal) capacity
Drain tube x two......................................... 424-98-11120
Refill capacity.............................................319 liter (84 gal)
1. Stop the engine and tighten corrosion resistor valve (1).
2. Turn radiator cap (2) slowly to remove it. When removing radiator
cap, first relieve internal pressure by turning the cap only a partial
rotation.
Remark
When flushing the cooling system it is important to catch and
recycle all used coolant. EPA and local regulations require all
engine fluids to be trapped and recycled.
3. Install drain hoses to valves (3 and 4). Prepare a container to catch the
coolant, then open drain valve (4) of the radiator and drain valve (3) on
the oil cooler to drain the coolant.
4. After draining the water, close drain valves (3 and 4) and fill with
non-mineral based water.
5. When the radiator is full, start the engine and run it at low idle. Open
drain valves (3 and 4), run the engine at low idle, and flush water
through the system for 10 minutes. While doing this, adjust the speed
of filling and draining so that the radiator is always full. While
flushing water through the system, watch the water inlet hose
carefully, be sure it does not come out of the radiator water filler neck.
6. After flushing, stop the engine, open drain valves (3 and 4), then close them again after all the water has drained out.
7. After draining the system, clean with a flushing agent. For details on the cleaning procedures, see the instructions given
with the cleaning agent.
8. After cleaning, open drain valves (3 and 4) to drain all the cleaning agent, then close them and fill slowly with clean
water.
9. When the water is close to the filler port neck, open drain valves (3 and 4), run the engine at low idle, and continue to run
water through the system until clean clear water flows out. When doing this, adjust the speed of filling and draining so the
radiator is always full.
10. When the water is completely clear, stop the engine, close drain valves (3 and 4).
WA900-3LC 3-27
MAINTENANCE
11. Replace the corrosion resistor cartridge and open valve. For details of replacement of the corrosion resistor, see “EVERY
1000 HOURS OF SERVICE” on page 3-68.
12. Add coolant until it overflows from the filler neck on the radiator. For details of coolant, see “FUEL, COOLANT AND
13. To remove air from the cooling system, run engine for five minutes at a low idle, then for another five minutes at high
idle. When doing this, leave radiator cap (2) off.
14. Stop the engine, wait for about three minutes, then add coolant up to the radiator water filler neck, then install and tighten
the radiator cap.
15. Drain, clean, and refill expansion tank.
CHECKING TRANSMISSION OIL LEVEL
When checking the oil level, apply the parking brake, and lock
the front and rear frames with the safety bar and pin.
The oil will be at high temperature after the machine has been
operated. Always wait for the temperature to go down before
starting this operation.
1. When carrying out this procedure look for any signs of oil on the
transmission case housing, or oil mixed with the coolant.
2. Stop the engine.
3. Use the sight gauge to check the oil level.
3-28 WA900-3LC
MAINTENANCE
4. If the oil level is not within the upper range A on the sight gauge, add
oil. For details on proper oil to use, see “FUEL, COOLANT AND
• Make an oil level check before starting engine or 60 or more minutes

after the engine is stopped. If oil remains at various levels, the correct
oil level cannot be measured. The oil level can also be measured at a
low idle. In this case the oil should be within the range at bottom of
area (B) on the sight gauge. However, the time taken for the oil level to
become steady will differ according to the idle speed and the oil
temperature.
5. If the oil is above the A, remove the cover plate from power train
guard. Remove the plug at the bottom of the drain valve (1) and install
the drain nipple (2). Connect the drain hose (3) to the nipple. Position a
container to catch the oil from the drain hose (3). Slowly loosen the
side plug (4) and allow oil to drain. After draining oil, tighten the side
plug. Remove the drain hose and nipple and install the bottom plug.
Recheck the level.
Side plug................. 49 to 78 Nm (36 to 58 lbf-ft)
Bottom plug............. 59 to 78 Nm (43 to 58 lbf-ft)
CHECKING AXLE OIL LEVEL
When checking the oil level, apply the parking brake, and lock
the front and rear frames with the safety bar and pin.
The oil will be at high temperature after the machine has been
operated. Always wait for the temperature to go down before
starting this operation.
Carry out this procedure if there is any sign of oil on the axle case housing.
Carry out the inspection with the machine on a horizontal surface. If the
road surface is at an angle, the oil level cannot be properly checked.
WA900-3LC 3-29
MAINTENANCE
1. Stop the engine and remove oil level plug (1).
2. Check the oil level, be sure it reaches the bottom of the plug hole.
3. If the oil is not close to the bottom edge of the housing plug hole, add
oil through the plug hole (1). For details on proper oil to use, see
“FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERA-
TURE CHART” on page 3-9.
4. If the oil level is correct, install plug (1).
Torque........................ 152 Nm (112 lbf-ft)
CHECKING AXLE CASE VENT
When cleaning, apply the parking brake, and lock the front and
rear frames with the safety bar and pin.
Perform the following:
3-30 WA900-3LC
MAINTENANCE
1. Remove any mud stuck to the area around the vent. Then, remove the
vent, immerse in cleaning fluid and clean.
2. When cleaning the breather vent, clean the vent at two places (front
and rear). Do not let dirt get into the port while vent is removed.
CHECKING WINDOW WASHER FLUID LEVEL

Do this when there is air in the window washer fluid. Check the washer
fluid levels in washer tanks (1) and (2). When the fluid has run short, add
automotive window washer fluid.
(1) Front window washing fluid tank
(2) Rear window washing fluid tank
To prevent the nozzles from clogging, be careful not to let dirt get into the
fluid.
CLEANING AIR CONDITIONER CONDENSER
Do not wash the condenser with a steam cleaner. Otherwise,

the condenser will get hot and may become damaged.
1. Open inspection cover (1) on the top of the floor.
2. Remove bolts from cover (2) of the air condenser.
WA900-3LC 3-31
MAINTENANCE
• If there is mud or debris in the air conditioner condenser, clean it
with warm low pressure water. Check the fins for clogging or
damage.
• If the water pressure is too high, the fins may be damaged. When
washing with a pressure washer, apply the water from a
reasonable distance.
• Use water only to wash the condenser. If necessary, use a soft
brush. Do not use a hard brush, as this will damage the fins.
CLEANING RADIATOR FINS

Carry out this procedure if there is mud or debris stuck in the radiator fins.
1. Remove bolt (1) and open radiator grill (2), then attach the lock. Use
compressed air to clean dust or leaves from the radiator fins. Steam or
water may be used instead of compressed air if build up is heavy. Be
careful when using high pressure steam or water. The high pressure
may damage the fins.
2. The hoses should be inspected at this time. If the hoses are found to
have cracks or to be hardened or soffened by ageing, they should be
replaced.
CHECKING INTAKE AIR HEATER SYSTEM

Check the electrical intake air heater once a year before commencing work in the cold season. Remove the air heater from the
engine intake connection, and check it for possible open circuits and debris build up. When inspecting or replacing the intake
heater, replace the gasket.
REPLACING BUCKET WEAR ITEMS
It is dangerous if the work equipment moves by mistake

when the teeth are being replaced. Set the work equipment
in a stable condition, then stop the engine, apply the parking
brake, put a warning tag on work equipment control levers
and remove ignition key.
The bucket wear items include teeth, lip protectors, corner end caps and the
vertical shrouds.
3-32 WA900-3LC
MAINTENANCE
Bucket Positioning For Servicing
1. Position the bucket on a stable support.
• Removal of the wear items is best carried out with the bucket
raised to a convenient height above the ground and resting on a
suitable and safe support.
Bucket Teeth
1. Using a pin removal tool and hammer, remove pin (1) from each tooth
and adapter. Discard pins and replace with new.
• The two tabs (A) on the pin have to break off the pin in order for
the pin to come off.
2. Remove the old tooth from adapter and discard. Clean away any
compacted dirt or material from the adapter nose.
3. Install a new tooth to the adapter nose aligning pin holes. Install the
pin into the tooth and adapter with the pin facing toward the tip of the
tooth.
4. Drive the pin in using minimal force. Concentrate on striking the rear
pin corner (B).
5. Drive pin in flush with top of the tooth.
• The pin spring (C) should lock inside the pin cavity.
• If the lip protectors are also being replaced at the same time as the
bucket teeth, leave the teeth out until all of the lip protectors are
replaced.
Lip Protectors
• The lip protectors (1) are secured to the bucket edge (2) with pins
through the teeth adapters (3). The teeth (4) also secure the lip
protectors in place on cutting edge.
WA900-3LC 3-33
MAINTENANCE
1. Remove the bucket teeth (1) at both sides of lip protector (2).
2. Using pin removal tool and hammer, remove both the lip protector
mounting pins.
• The tabs on the mounting pins have to be broken off to allow

removal of pin.
3. Clean mounting supports and teeth adapters. Check the lip protector
mounting supports for wear and damage. Remove dirt from lip
protector stabilizers.
4. Place each lip protector (right x 4, center and left x 4) in position on

lip. Make sure the rear tang of each lip protector is engaged in its
stabilizer (A).
3-34 WA900-3LC
MAINTENANCE
Corner End Cap
• The corner end caps are locked in place by the corner bucket
teeth.
1. Remove the each corner bucket tooth as described previously.
2. Slide the end cap forward then outward and remove from bucket.
Repeat for the remaining side.
3. Examine the lugs on each corner adapter for any wear or damage and
clean any dirt from the slots.
4. Insert the corner end cap all the way into the retaining slots of the
corner adapter, then slide the end cap towards the back of the bucket.
Repeat for the remaining side.
5. Install the bucket teeth to the corner adapters as described previously.
Vertical Shrouds
1. Remove pins (1) from each vertical shroud (2). Lift the shrouds from
the two supports.
2. Remove old rubber keepers (3) and discard. Insert new keepers into
shroud support.
3. Insert the vertical shroud in place by lowering on the top and bottom
shroud supports. Insert pins, tapered end in, flush with the surface of
shroud.
WA900-3LC 3-35
MAINTENANCE
LUBRICATION
Apply the parking brake switch, and lock the front and rear
frames with the safety bar and pin.
Set the work equipment on a stable surface, then stop the
engine, put a warning tag on work equipment control levers
and remove ignition key.
1. Clean the grease fitting off with a shop towel before hooking up the
grease pump gun.
2. Using a pressurized grease pump, pump in grease through the grease

fittings shown by arrows.
3. After greasing, wipe off any old grease that was pushed out.
Work Equipment Control Valve Linkage
If the work equipment control lever is heavy or does not move smoothly,
apply grease at 2 points.
3-36 WA900-3LC
MAINTENANCE
Boom and Bucket Linkage
Grease the following items listed below every 10 operating hours or every
day for the first 50 operating hours until the pins have completed initial
wear in on a new machine.
1. Bucket pin................................................................................ 2 points
2. Bucket link pin......................................................................... 2 points
3. Boom hinge pin...................................................................... 2 points
4. Bucket cylinder pin................................................................ 2 points
5. Tilt lever pin........................................................................... 1 point
6. Boom cylinder pin.................................................................. 4 points
WA900-3LC 3-37
MAINTENANCE
CHECKING AIR CONDITIONER
Check twice a year, spring time and autumn.
Never loosen or disconnect air conditioner refrigerant

hoses, lines, component plugs or connection. Escaping
refrigerant may cause loss of sight or frostbite.
Operate the air conditioning system for 5 to 10 minutes, then measure the
temperature coming out of the cab air ducts by hand. Be sure the
temperature control is set in the cool mode. See “AIR CONDITIONER” on page 2-33.
If the air temperature feels warm or it is not cool enough, check the fuse in the fuse panel. See“FUSE CAPACITY AND CIR-
CUIT” on page 2-66. Check the refrigerant compressor belt, see if it is loose or missing. If air conditioner controls,
fuse or compressor belt are in operating condition and the air temperature coming from the air ducts is still below desired
temperatures, contact your distributor concerning an inspection of the air conditioner system.
Operating The Air Conditioner Off Season
To lubricate each portion of the refrigerant compressor or air conditioning system during the off season, operate the air
conditioner for 3 to 5 minutes once a month. Be sure to idle engine at low speed when doing this procedure.
ADJUSTING PARKING BRAKE
When adjusting the parking brake, be sure to put blocks

under the tires to prevent the machine from moving.
When carrying out any adjustment, the brake circuit
accumulator oil pressure must be high enough to prevent
the parking brake from being applied automatically.
Be sure to hang a caution tag on the turn signal lever to
prevent any person from operating it.
Take care not to get oil or grease on the brake pad and the
disc surface.
If the parking brake fails to work properly, adjust as follows:
1. Release the parking brake.
3-38 WA900-3LC
MAINTENANCE
2. Turn bolt (1) counterclockwise while pressing bolt retainer (2) and
let pads (3) on both sides come into close contact with disc (4).
3. Turn back bolt (1) a half turn clockwise while pressing bolt
retainer (2).
4. Return bolt retainer (2) to the original position and confirm that
the retainer is in the locking position for bolt (1).
• Adjust the brake on the opposite side according to steps 1

through 4 above.
• Check the lining for wear and replace the pad if the thickness
of the lining is less than 3 mm (0.12 in). Ask your
distributor for replacement pads.
BLEEDING AIR FROM BRAKE CIRCUIT

After removing the piping from the brake hydraulic circuit, bleed the air
from the circuit as follows:
1. After assembling the piping, tighten all the connectors.
2. Put blocks under the wheels.
3. Check to be sure the brake oil level, is within the sight gauge on the
side of the brake oil tank.
A- When checking 10 hours or more after the engine is stopped, use

the upper level gauge.
B- When checking 5 minutes or more after the engine is stopped, use

the lower level gauge.
4. Stop the engine.
5. Remove the air bleeder cap from the brake housing and insert one end
of a vinyl hose in the brake housing and put the other end into a
container half full of clean hydraulic oil.
6. Depress the brake pedal and loosen bleeder screw (1) to bleed air.
After tightening bleeder screw, release the brake pedal slowly.
WA900-3LC 3-39
MAINTENANCE
Remark
This work should be performed by two persons. One depresses the brake pedal, and the other bleeds air
through the bleeder screw (1). Use the left brake pedal. Supply brake oil periodically to keep the level
sufficiently high.
7. Repeat this operation until air bubbles stop coming out of the hose. Then, depress the pedal and tighten bleeder screw (1)
while the oil is flowing out.
8. Bleed the air at all four wheel locations. After bleeding the air, check the oil level in the brake oil tank. For details, contact
your distributor.
BLEEDING AIR FROM PPC CIRCUIT

When removing piping on PPC circuit, or removing strainer, after assembling, bleed air from inside of the circuit as follows:
1. Set the bucket control lever in the TILT position and boom control lever in the FLOAT position, after the cylinder reaches
it’s end stroke, hold that position for one minute.
2. Set the bucket control lever in the DUMP position and boom control lever in the RAISE position, after the cylinder
reaches it’s end stroke, hold that position for one minute. For details, contact your distributor.
BLEEDING AIR FROM HYDRAULIC TANK

1. After replacing oil and filter element or cleaning the strainer, bleed the air from the circuit.
2. When changing hydraulic oil, removing the pump, or piping, it is important to bleed all air from the hydraulic system.
Bleeding Air from Hydraulic Circuit
1. Check the oil level in the hydraulic tank. Run the engine at low idle
and operate each hydraulic cylinder (on steering, bucket and boom)
4 to 5 times, stopping 100 mm (3.94 in) from stroke end.
2. Next, operate each cylinder 3 to 4 times to the end of its stroke, then
stop the engine and loosen air bleed plug (1) on the hydraulic tank to
bleed the air. After bleeding the air, tighten the plug. Check the
hydraulic oil level and add oil if necessary, see “EVERY 100 HOURS
OF SERVICE” on page 3-52.
3. Increase the engine speed and repeat step 2 to bleed the air until no more bubbles come out from plug (1). If the engine is
run at a high speed at first or if the cylinder is moved to the end of its stroke, the air in the cylinder may damage the piston
packing, etc. After bleeding the air, tighten the air bleeding plug (1).
Plug............................................ 11.3 Nm (8.3 lbf-ft)
4. Check the oil level in the hydraulic tank and add oil if necessary. After adding oil, tighten the oil filler cap securely. For
proper oil to use, see “FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE CHART” on page 3-9.
Check hydraulic oil level, see “EVERY 100 HOURS OF SERVICE” on page 3-52.
3-40 WA900-3LC
MAINTENANCE
BLEEDING AIR FROM THE PUMP
If air is not bleed completely, the pump may be damaged, always carry out
the air bleeding operation correctly.
Before bleeding the air from the pump, check the hydraulic oil level in the
hydraulic tank, if low, fill it to the specified level.
1. Loosen oil filler cap (1).
2. Loosen plugs (2), (3) and (4) on the tubes at the suction side of each
piston pump. There is one plug for each pump, loosen all three plugs.
Allow all air to escape from each plug, when non-aerated oil comes
out, tighten the plugs back up.
3. Check oil level and oil if necessary. Tighten the oil filler cap securely.
4. Loosen connector (5) at the block side of the case drain hose (6) of the
piston pump. There are three case drain hoses connected to the block,
loosen only the connector of hose (6) connected to the top of the block.
5. Run the engine at low idle and let aerated oil and air escape from
around the connector until no air is evident. This process may require
10 minutes.
6. Tighten connector (5).
7. Check the oil level and add oil if necessary.
• For details, contact your Komatsu distributor.
WA900-3LC 3-41
MAINTENANCE
REPLACING SLOW BLOW FUSE
Remark
Always turn the power OFF when replacing the slow blow fuse (turn the ignition switch to
the OFF position). Always replace the slow blow fuse with a fuse of the same capacity.
1. Turn the ignition switch to the OFF position.
2. Remove the slow blow fuse box from the chassis.

(1) Main power..................................................................................................................120 Amp
(2) Battery power................................................................................................................30 Amp
3. Open covers (1), (2) and (3) of the slow blow fuse box. Covers (2) and
(3) can be removed easily by using protrusion A on the body, as a
fulcrum, catch of the cover with a flat headed screwdriver to release it.
4. Loosen screws (4) and (5) and remove. When screws (4) and (5) are
removed, slow blow fuse (6) will also come off together with electrical
wiring (7) and (8).
5. Using screws (4) and (5), install a new slow blow fuse together with
electrical wiring (7) and (8). When finished, close covers (1), (2)
and (3).
6. Install the slow blow fuse box to the chassis.
3-42 WA900-3LC
MAINTENANCE
REPLACING FAN BELT AND AUTO TENSIONER
Replace the belt if it contacts the bottom of the pulley groove or if there are
any cracks, peeling or other damage to the belt.
1. Remove fan guard. Loosen nut on belt tensioner until belt can be
removed from pulley. Remove belt. When a new belt is installed, it
should be checked with the belt tensioner tool. A reading of 400 to
489 Nm (90 to 100 lb-ft) should be obtained. If not, loosen auto
adjuster and adjust idler pulley to reduce belt clearance, then tighten
auto adjuster.
• Belt tension should be checked every 400 to 500 hours.
2. Make sure belt is not rubbing on any external components. Install

fan guards. Run engine and inspect for belt alignment.
SELECTION AND INSPECTION OF TIRES
If a tire or a rim is handled incorrectly, the tire may burst or

the rim may be broken and scattered, causing serious injury
or death.
• Since maintenance, disassembly, repair and assembly of
tires and rims require special equipment and skill, have a
tire repair shop to carry out the work.
• Do not heat or weld on the rims.
WA900-3LC 3-43
MAINTENANCE
Selection of Tires
1. Select the tires according to the conditions of use and attachments on the machine. Use only specified tires and inflate
them to the specified pressure.
2. Since speeds varies with the tire size, consult your distributor when using optional tires.
Checking Tire Pressure and Inflating Tires
• When inflating a tire, be sure no one will enter the working area. Use an air chuck which has a clip and can be fixed to the
air valve. While inflating the tire, check the pressure occasionally so it will not rise too high. If the rim is not fitted
normally, it may be broken and scattered while the tire is inflating the tire. To ensure safety, place a guard around tire and
do not work in front of the rim, work on the tread side of the tire.
• Drop in inflation pressure and abnormal fitting of the rim indicate a trouble in the tire or rim. In this case, be sure to have
a tire repair shop carry out repairs. Be sure to observe the specified inflation pressure. Do not adjust inflation pressure of
the tires just after high speed travel or heavy duty work.
Check
• Measure the inflation pressure with a tire pressure gauge while the
tires are cool before starting work.
Inflation of tires
• Adjust the inflation pressure properly. When inflating a tire, use

an air chuck which can be fixed to the valve of the tire. Do not
work in front of the rim, work on the tread side of the tire.
• The appropriate tire inflation pressure differs according to the

type of work, see “HANDLING THE TIRES” on page 2-104.
3-44 WA900-3LC
MAINTENANCE
CLEANING HIGH PRESSURE STRAINER
• If there is any abnormality in the pump or other hydraulic equipment,
remove the dirt from inside the in line strainer as follows.
• Before removing the in line strainer, release the pressure inside the
hydraulic circuit. For details, see “OUTLINE OF SERVICE” on
page 3-5.
1. Remove four bolts and flange, then temporarily insert two of the
bolts (1) back into cover (2) diagonally on opposite sides.
2. Loosen clamp (1 place).
3. Remove cover (2), and clean strainer (5).
(1) When cleaning the filter, also clean off the dirt and dust stuck to
the side face of the case.
(2) When assembling the case again, replace o-ring (5) and o-ring (3)
and backup ring (4) together. Install cover (2).
Cover torque......................................... 108 Nm (79 lbf-ft)
(3) After assembling the in line strainer, bleed the air from the
system. For details, see “BLEEDING AIR FROM HYDRAULIC
TANK” on page 3-40.
WA900-3LC 3-45
MAINTENANCE
CHECKS BEFORE STARTING WORK CYCLE
Be sure to put a warning tag on work equipment control levers.
CHECKING MONITOR PANEL

Turn the ignition switch to the ON position. Check all the monitor lamps,
gauges and the warning lamp, be sure they light up for about 3 seconds and
the alarm buzzer sounds for about 1 second.
If any monitor lamp does not light up, ask your distributor to inspect the
monitor lamp circuit. Do not carry out the checks before starting using only
the monitor; always carry out the items specified for periodic maintenance.
3-46 WA900-3LC
MAINTENANCE
CHECKING COOLANT LEVEL
Do not remove the radiator cap while coolant is hot. Hot

water may spout out. When removing the radiator cap,
slowly rotate the cap to relieve the internal pressure.
1. Check coolant level on level ground, be sure the level is between the
FULL and LOW marks.
2. Open the access door on the left platform near the cab. Remove radia-
tor cap at the top of the tank and add coolant. Tighten the
cap securely. For details of coolant, see “FUEL, COOLANT AND
• If the volume of coolant is more than usual, check for possible

leakage. Confirm that there is no oil in the coolant.
CHECKING OIL LEVEL IN ENGINE

1. Open the door at the rear left side of the machine.
2. Remove dipstick and wipe the oil off with a cloth.
3. Insert dipstick fully in the tube, then take it out again.
4. The oil level should be between the H and L marks on dipstick. If the
oil level is below the L mark, add engine oil through oil filler. For
details of the oil to use, see “FUEL, COOLANT AND LUBRICANTS
WA900-3LC 3-47
MAINTENANCE
5. If the oil is above the (H) mark, drain the excess engine oil from drain
valve and check the oil level again.
6. If the oil level is correct, tighten the oil filler cap securely, then close
the door.
Remark
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
checking.
If the machine is at an angle, level it before checking the oil.
CHECKING BRAKE OIL TANK LEVEL

Remark
Always use engine oil to refill the brake oil tank. Do not
substitute oils.
7. Check the oil level in the brake oil tank on the left side of the machine
from the ground, be sure it is within sight gauge (1) installed on the
side of the brake tank.
A- When checking 10 hours or more after the engine is stopped, use

the upper level gauge shown in the figure on right.
B- When checking 5 minutes or more after the engine is started, use

the lower level gauge in the figure at right.
8. If the oil level is low, open the cover on the top of the platform, then
open the cap and add engine oil. For details on the oil to use, see
“FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERA-
TURE CHART” on page 3-9.
3-48 WA900-3LC
MAINTENANCE
CHECKING FUEL LEVEL
When adding fuel, never let the fuel overflow. This may
cause a fire. If you spill fuel, thoroughly clean up any
spillage. Never smoke while refueling or checking fuel levels
at the fuel tank.
1. Turn the engine ignition switch to the ON position, then check the fuel
level with fuel gauge. After checking, return the ignition switch to the
OFF position.
2. Upon completion of work, remove the fuel cap and add fuel through
filler until the fuel tank is full.
• For details on the opening and closing the cap, see “CAP LOCK” on
page 2-63. For details on fuel to usage, see “FUEL, COOLANT AND
3. After adding fuel, tighten the cap securely.
Fuel capacity................................................. 1425 liter (376 gal)
CHECKING ELECTRICAL WIRING

• If fuses are frequently blown or if there are traces of a short circuit in the electrical wiring, locate the cause and carry out
repairs immediately.
• Accumulation of flammable material (dead leaves, twigs, grass, etc.) around the battery may cause a fire, always check for
and remove such material.
• Keep the top surface of the battery clean and check the cap vent holes on the battery. If they are clogged with dirt or dust,
wash the battery with a warm water and baking soda solution.
• Check for damage, wrong capacity fuse or any sign of disconnection or short circuit in the electric wiring.
• Check for loose terminals tighten any loose connections. Check the battery, starting motor and alternator wiring carefully.
When carrying out a walk around check or checks before starting, always check if there is any accumulation of flammable
materials around the battery, remove such material. Contact your distributor for investigation if needed.
WA900-3LC 3-49
MAINTENANCE
CHECKING TIRES INFLATION PRESSURE
Measure the inflation pressure with a tire pressure gauge while the tires are
cool before starting work. Check for damage or wear on the tires and the
rims. Check for loose wheel hub nuts.
Remark
The appropriate tire inflation pressure differs according to the
type of work, so see “HANDLING THE TIRES” on page 2-104.
CHECKING EFFECT OF PARKING BRAKE SYSTEM
Even if the parking brake switch (1) is turned ON, there is

danger until parking brake lamp (2) lights up, it is important
to keep brake pedal (3) depressed.
Measurement Conditions
• Tire inflation pressure................. Specified pressure

• Road surface.............. Dry pavement with 1/5 grade
• Machine.................................... Operating condition
3-50 WA900-3LC
MAINTENANCE
Measurement Procedures
1. Turn the key ignition switch to the ON position and start the engine,
set the machine facing straight, then drive the machine up a 1/5 grade
with the bucket empty.
2. Depress brake pedal, stop the machine, return directional lever to the
neutral position, then stop the engine.
3. Set the parking brake switch in the ON position, release brake slowly,
and check that the machine, be sure it is held in position.
CHECKING EFFECT OF BRAKES

Drive the machine at a speed of 20 km/h (12.4 MPH) on a dry flat concrete
road surface, and check that the stopping distance, see if it is less than
7.5 m (24 ft 6 in).
CHECK HORN AND BACKUP ALARM
CHECK LAMPS, FOR DIRT OR DAMAGE
CHECK REAR VIEW MIRROR FOR DIRT OR DAMAGE
CHECK ENGINE EXHAUST COLOR AND SOUND
CHECK OPERATION OF GAUGES
CHECK PLAY AND OPERATION OF STEERING
EVERY 50 HOURS OF SERVICE

levers and remove ignition key.
DRAINING WATER AND SEDIMENT FROM FUEL TANK
This procedure should be done at the start of each work day.
1. Loosen valve (1) on the right side of the tank, the sediment and water
will be drained together with fuel.
WA900-3LC 3-51
MAINTENANCE
EVERY 100 HOURS SERVICE

Maintenance for every 50 hours should be carried out at the same time.
LUBRICATION
Apply the parking brake, and lock the front and rear frames
with the safety bar and pin.
Set the work equipment in a stable condition, then stop the
engine, tag the work equipment control levers and remove
ignition key.
1. Be sure to clean the grease fittings off before hooking up the grease
pump.
2. Using a grease pump, pump in grease through the grease fittings

marked by the arrows.
3. After greasing, wipe off any old grease that is pushed out.
3-52 WA900-3LC
MAINTENANCE
(1) Bucket pin.................................................................................. 2 points
(2) Bucket link pin........................................................................... 2 points
(3) Boom hinge pin.......................................................................... 2 points
(4) Bucket cylinder pin.................................................................... 2 points
(5) Boom lever pin............................................................................ 1 point
(6) Boom cylinder pin...................................................................... 4 points
WA900-3LC 3-53
MAINTENANCE
(7) Steering cylinder pin.................................................................. 4 points
(8) Rear axle pivot pin..................................................................... 3 points
3-54 WA900-3LC
MAINTENANCE
CHECKING OIL LEVEL IN HYDRAULIC TANK
When the oil filler cap is removed, there is a chance oil may
spurt out, stop the engine and wait for the oil
temperature to go down, then turn the cap slowly to release
any internal pressure before removing the cap.
If oil has been added above the H mark, stop the engine and
wait for the hydraulic oil to cool down, then drain the excess
oil from the system.
1. Lower the bucket completely to the ground and stop the engine.
Wait for 5 minutes, then check sight gauge (1). The oil level should
be between the H and L marks.
Remark
Do not add oil if the level is above the H line. This will damage
the hydraulic equipment and cause the oil to spurt out.
2. If the oil is below the L level, open the inspection cover above the
step and add oil through oil filler port (2). For details on the oil to
use, see “FUEL, COOLANT AND LUBRICANTS AMBIENT TEM-
PERATURE CHART” on page 3-9.
AIR CONDITIONER FRESH AIR FILTER
When using compressed air, wear safety glasses or other

personal protective equipment to maintain safety.
If the air conditioner has been used, the air filter should be cleaned.
Shut the air conditioning system down before cleaning the element.
1. Hold knob (1) and open cover (2).
2. Loosen screw (3), then take the element (4) out and clean it.
3. Blow dry compressed air along the folds from the inside of the
element. Next, blow air along the folds from the outside, then
blow from the inside again.
Remark
Never use more than 3.5 kg/cm (50 psi) of air pressure to clean
the element. When assembling the element again, install so that
the arrow on top of the element is facing the inside of the cab.
WA900-3LC 3-55
MAINTENANCE

Maintenance for every 50 hours should be carried out at the same time.
CHECKING BATTERY ELECTROLYTE LEVEL
To avoid gas explosions, do not bring fire or sparks near the

battery.
Battery electrolyte is dangerous. If it gets in your eyes or on
your skin, wash it off with large amounts of water, and con-
tact a doctor.
Carry out this check before operating the machine.
1. Open the cover of the battery box. There are two battery boxes: One on each side at the rear of the machine.
2. Remove cap (1) and check the battery electrolyte, be sure it is up to the upper level line. If the level is low, add distilled
water, do not add water above the upper level line. This may cause leakage of electrolyte.
3. Clean the vent hole in the battery cap, then tighten the cap securely. Wipe the top surface of the battery with a damp cloth
to keep it clean.
Remark
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the
electrolyte from freezing.
CHECKING ALTERNATOR BELT TENSION
Checking Adjustment
The belt should normally deflect by about 20 mm (0.79 in) when

pressed with the finger [with a force of 59 Nn (13 lb-ft)] at a point
midway between the drive pulley and alternator pulley.
3-56 WA900-3LC
MAINTENANCE
Adjusting Tension
1. Loosen lock nuts (1). Rotate adjusting link (2) so the deflection is
20 mm (0.79 in) at a force of. 59 Nn (13 lb-ft). After adjustment,
tighten lock nut (1) securely.
2. Check each pulley for damage, wear in the grooves, and wear on
the belt. Be sure to check and see if the belt is not touching the
bottom of the groove. Replace the belt if it has stretched, leaving
no allowance for adjustment, or if there is any cuts or cracks.
3. After operating the machine for one hour with a new belt, test
and adjust the belt again.
AIR CONDITIONER RECIRCULATION FILTER

1. Open the filter inspection cover (1), remove the filter cover (2),
then remove the filter in the direction of the arrow. When removing
the filter, put your weight on the seat, and push down.
2. Clean with dry compressed air in the same way as for the fresh air
filter. If the filter is extremely dirty, rinse it in water. After rinsing
the filter, dry it completely before installing it again.
CHECKING REFRIGERENT COMPRESSOR BELT TENSION

Checking a Used Belt
The deflection should be 12.5 to 16.5 mm (0.5 - 0.7 in) when pressed with a finger force of 98 Nm
(22 lb-ft) at a point midway between the compressor pulley and drive pulley. When using a belt
tension gauge, the tension should be in a range of 353 to 530 Nm (79 to 119 lb-ft).
Checking a New Belt
The deflection should be 9 to 12.5 mm (0.35 to 0.5 in) when pressed with a finger force of 98 Nm
(22 lb-ft) at a point midway between the compressor pulley and drive pulley. When using a belt
tension gauge, the tension should be in a range of 530 to 745 Nm (119 to 167 lb-ft).
Adjusting
1. Loosen top locknut (1). Turn lower adjustment nut (2) to adjust the belt tension to the
specified value. After adjusting, tighten locknut (1).
• Deflection when checking........ 12.5 to 16.5 mm (0.5 - 0.7 in) 98 Nm (22 lb-ft)
• Deflection when replacing........ 9 to 12.5 mm (0.355 - 0.5 in) 98 Nm (22 lb-ft)
2. Check each pulley groove for damage or wear, check the belt for wear. Be sure to check and see if
the belt is not touching the bottom of the groove. If the belt is elongated and there is no more
allowance for adjustment, or if the belt is cut or cracked, replace it with a new belt.
3. After replacing the belt, operate the machine for one hour, then check and adjust again.
WA900-3LC 3-57
MAINTENANCE
CHECKING FOR LOOSE WHEEL HUB NUTS
If wheel hub nuts (1) are loose, tire wear will be increased and
accidents may be caused.
1. Check for loose nuts, and tighten if necessary. When checking,

always turn the nuts in the direction of tightening to check.
Nut torque........................................ 471 Nm (347 lbf-ft)
2. If any wheel bolt is broken, replace all bolts for that wheel.
CHECKING FRAME AND BOOM

1. Wash the frame and boom so the check can be carried out easily.
2. Check all parts of the frame and boom for damage. In particular,
check the hatched parts in the diagram, and repair if any cracks
or other damage is found. For details on the method of repair,
contact your distributor.
3-58 WA900-3LC
MAINTENANCE

Maintenance for every 50, 100 and 250 hours should be carried out at the same time.
CHANGING ENGINE OIL AND FILTER CARTRIDGES
The oil is at high temperature after the engine has been running, never change the oil immediately after
finishing operations. Wait for the oil to cool down before changing it.
Oil catch container...................... Min. 140 liter (37 gal) capacity
Filter wrench........................................................ 09019-08035
Drain tube........................................................... 424-98-11120
Refill capacity................................................ 132 liter (34.8 gal)
1. Open the engine side cover located on the left of machine.
2. Open the oil filler tube (1).
3. Place a container to catch the oil under drain valve (2) on the left
side of the machine.
4. Prior to draining the oil, install the drain tube to the drain valve (2)
to prevent the oil from spilling. Loosen the drain valve (2) and
drain the oil.
5. Check the drained oil, and if there are excessive metal particles or
foreign material, contact your distributor.
6. Tighten the drain valve (2).
WA900-3LC 3-59
MAINTENANCE
7. Using the filter wrench, remove the four full flow filter cartridges (3).
Remark
If this operation is carried out immediately after stopping the
engine, a large amount of oil will come out of the filter, wait for
10 minutes before starting the operation.
8. Using the filter wrench, remove the two bypass filter cartridges (4).
9. Clean the six filter headers.
• The external appearance of the full flow filter element (A) and
the by pass filter element (B) are the same. The full flow filter
element contains 1-½ 16 threads. The by pass filter element
contains 1- 3/8 16 threads.
3-60 WA900-3LC
MAINTENANCE
• Coat the seal and thread of the filter cartridge with engine oil.
Fill the new filter cartridge with engine oil.
Remark
The lack of lubrication during the delay time on engine start
up until the filter is pumped full of oil is harmful to the engine.
Always fill each filter with clean oil before installing them.
10. When installing, bring the seal surface into contact with the
filter holder, then tighten a further ¾ to 1 turn by hand.
11. Use oil filter wrench, tighten the filter to specifications supplied
with filter.
12. After replacing the filter cartridge, add engine oil through oil filler
(5) until the oil level is between the H and L marks on dipstick (6).
For details of the oil to use, see “FUEL, COOLANT AND LUBRI-
WA900-3LC 3-61
MAINTENANCE
13. Run the engine at idle for a short time, then stop the engine, and
check the oil level is between the H and L marks on thedipstick.
• If the machine has not been operated for 250 hours, the oil and
filter cartridge must be replaced when the machine has been
operated for 6 months. Use API category CD class oil. If CC class
oil must be used, change the oil and replace the oil filter at half
the usual interval (125 hours).
REPLACING FUEL FILTER CARTRIDGE
Engine is at a high temperature immediately after the machine has been operated. Wait for engine to cool
down before replacing the filter.
Do not smoke or have any open flames near when servicing fuel system.
Prepare a filter wrench and a container to catch any fuel spillage.
Fuel catch container...................... Min. 3.8 liter (1 gal) capacity
Filter wrench.......................................................09019-08035
1. Open the side panel located on the right of the machine and secure
the lock open.
2. Set the container to catch the fuel under the filter cartridges. Turn
fuel stop lever (1) toward you to prevent the fuel from dripping.
3. Using filter wrench, remove the fuel turn filter cartridge (2).
3-62 WA900-3LC
MAINTENANCE
4. Use a clean, lint free towel to clean the filter header gasket surface.
5. Coat the packing surface with engine oil. Fill new filter cartridge
with clean fuel.
6. Install filter element to the header and tighten until the packing
surface contacts the seal surface of the header, then tighten
it ½ to ¾ of a turn by hand. If the filter cartridge is tightened too
far, the packing will be damaged and this will lead to leakage of fuel.
If the filter cartridge is too loose, fuel will also leak from the packing.
7. After replacing filter cartridge (2), fully open fuel stop lever (1),
then loosen the hose fitting (3) at filter header.
WA900-3LC 3-63
MAINTENANCE
8. Move the feed pump knob (4) up and down to draw off fuel until
air ceases to come out of the loosened hose. After bleeding air,
tighten the hose fitting.
When cranking the engine, check the area around the

engine, as the engine may start. Be sure all personnel are
clear of your work area.
9. After replacing the filter cartridges, turn the ignition switch to the START position. When the engine starts, check for any
leakage from the filter seal surfaces. If there is any leakage, check the filter cartridges. If there is still any leakage, follow
steps 2 and 3 to remove filter cartridge, and check packing surfaces. If there is any damage or any dirt or dust caught in the
surface, replace the cartridge with a new part, then repeat steps 4 to 7.
REPLACING TRANSMISSION OIL FILTER
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before
carrying out maintenance.
Prepare a container to catch the drained oil.
3-64 WA900-3LC
MAINTENANCE
1. Loosen bolt and open the side panel.
2. Set the container to catch the oil under the filter case.
3. Remove drain plug (1) at the bottom of the filter case, and drain the
oil. After draining the oil, tighten the plug.
4. Hold case (2) and loosen hexagon part (3) of case, then remove case.
5. Remove the element (4) and retainer (5) and clean the inside of
the case. Replace the o-rings (6 and 7) with new parts.
6. Coat the o-ring (6 and 7) with clean engine oil before installing.
7. Install o-ring (6) to header. Assemble the new element (4), set it in
the case, then install with case nut (3).
Case nut................. 59 to 78 Nm (43 to 57 lbf-ft)
8. Install o-ring (7) to drain plug (1) and install to case.
Drain plug.............. 49 to 59 Nm (36 to 43 lbf-ft)
9. Run the engine at idle for a short time, then check the oil level.
For details, see “FUEL, COOLANT AND LUBRICANTS AMBIENT
TEMPERATURE CHART” on page 3-9.
WA900-3LC 3-65
MAINTENANCE
LUBRICATE CENTER DRIVE SHAFT
ignition key.
pump.

marked by the arrows.
3-66 WA900-3LC
MAINTENANCE
CHECKING FAN BELT FOR WEAR

Check the belt for the following conditions, replace or adjust if needed.
1. When the belt makes contact with the bottom of the grooves in
each pulley.
2. When the belt is worn, and its surface is lower than the outer
diameter of the pulley.
3. When the belt is cracked or flaked.
4. When the belt makes an abnormal noise.
• Since an auto tensioner is installed, the belt does not need to be adjusted until it is replaced. For details on
replacement procedure, see “WHEN REQUIRED” on page 3-24.
WA900-3LC 3-67
MAINTENANCE

Maintenance for every 50, 100, 250 and 500 hours should be carried out at the same time.
CHANGING TRANSMISSION OIL AND CLEANING STRAINER
ignition key.
The oil is at a high temperature immediately after the
machine has been operated. Wait for the oil to cool down
before carrying out maintenance.
Oil catch container.................. Min 140 liter (37 gal) capacity
Refill capacity................................................140 liter (37 gal)
Drain nipple.................................................. 424-98-11110
Drain hose..................................................... 424-98-11120
3-68 WA900-3LC
MAINTENANCE
1 Remove cover plate from power train guard.
2. Remove the plug at the bottom of the drain valve (1) and install the drain nipple (2). Connect the
drain hose (3) to the nipple. Position a container to catch the oil from the drain hose (3). Slowly
loosen the side plug (4) and allow oil to drain completely. There is a stop in the valve that
prevents removal of the side plug. After draining oil, tighten the side plug. Remove the drain hose
and nipple and install the bottom plug.
Side plug........................................................... 49 to 78 Nm (36 to 58 lbf-ft)
Bottom plug...................................................... 59 to 78 Nm (43 to 58 lbf-ft)
3. Set a container to catch the oil under the transmission filter. Remove
transmission filter drain plugs (4) (6 pieces), drain the oil, then tighten
the plug again.
Drain plug................................. 49 to 59 Nm (36 to 43 lbf-ft)
4. Remove front guard access cover.
WA900-3LC 3-69
MAINTENANCE
5. Remove bolt (5), then remove cover (6) and take out strainer (8)
together with spring (7).
6. Remove any dirt stuck to strainer (8), then wash it in clean non
flammable cleaning solvent. If strainer is damaged, replace it with a
new part.
7. Install spring (7) and strainer (8) to cover. Replace the o-ring on the
cover with a new part, then install the cover.
8. Pour in the specified amount of engine oil through oil filler (9). For
details on oil to use, see “FUEL, COOLANT AND LUBRICANTS
9. Check for oil leakage from the 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.
10. Replace power train cover plate.
CLEANING TRANSMISSION CASE VENT

1. Remove mud and dirt from around the vent cover, then remove the
cap. Install a clean vent cap.
2. Be careful not to allow dust and dirt to enter the transmission case
through the port while the vent cap is removed.
3-70 WA900-3LC
MAINTENANCE
LUBRICATION
ignition key.
pump.

marked by the arrows
(1) Center hinge pin......................................................................... 2 points
WA900-3LC 3-71
MAINTENANCE
(2) Drive shaft center support............................................................ 1 point
(3) Front drive shaft......................................................................... 3 points
(4) Rear drive shaft.......................................................................... 3 points
3-72 WA900-3LC
MAINTENANCE
(5) Upper drive shaft........................................................................ 3 points
6. Parking brake linkage.................................................................. 6 points
(7) Torque converter mount trunnion................................................. 1 point
WA900-3LC 3-73
MAINTENANCE
8. Engine fan end trunnion............................................................................................................ 1 point
CHECKING PARTS OF TURBOCHARGER

Do not tamper with the turbocharger system, do not remove compressor or turbine piping. Contact your distributor to have
them tightening and perform checks.
CLEANING FUEL STRAINER

1. Using hex, 24mm across flats, at bottom of housing (1) remove
housing from header (6). Remove strainer element (4), o-ring (3) and
back up ring (2) from header (6).
Remark
Check condition of o-ring (5) in strainer element (4), if
damaged,replace complete strainer element.
2. Remove all dirt from the surface of the strainer element (4), then wash
in clean non-flammable solvent. If strainer is damaged, replace with a
new part.
3. Install strainer element (4) to header (6). Install o-ring (3), on top, and back up ring (2) to header.
Install housing (1) to header and tighten using housing hex, 24mm across flats.
Housing torque................................................................ 24 to 34 Nm (18 to 25 lbf-ft)
CHECKING ROPS CANOPY

1. Loosen the bolt, then remove the cover.
2. Check for loose mounting bolts (1) on the ROPS canopy. If any bolt is
loose, tighten it. Reinstall the cover.
Bolt torque............................................. 2,746 Nm (2,025 lbf-ft)
3-74 WA900-3LC
MAINTENANCE
CORROSION RESISTANCE CARTRIDGE
The corrosion resistance cartridge is a spin on type cartridge. This cartridge
cannot be cleaned or disturbed except when it becomes necessary to
replace it. Replace the corrosion resistor cartridge at every engine oil
change. The correct corrosion resistor cartridge to be used is determined by
the total cooling system capacity and operational factors. For further infor-
mation, see “SUPPLEMENTAL COOLANT ADDITIVES” on page 3-13.
The corrosion resistor cartridge is located on the left side of the engine. Be
careful not to allow dirt, water or other foreign material to get in the new
cartridge. Keep new cartridges in the original package until ready for
installation.
Replacement
• Do not remove the radiator cap when the engine coolant

is hot. Hot coolant will cause serious personal injury.
• Remove the radiator cap and close the shut off valve,
before removing the corrosion resistance cartridge.
Failure to do so can result in personal injury from heated
coolant spray.
1. Open the engine side access door on the left side of the machine.
Remove the radiator cap.
2. Turn shut off valve (1), located on the left side of the engine, to
the OFF position. Clean the area around the corrosion resistor.
cartridge.
3. Using a filter wrench, remove. Discard cartridge in a suitable

manner if is not needed for any reason.
4. Clean the cartridge gasket surface on the cartridge header.
5. Apply a thin coat of clean engine oil to the seal of the new cartridge.
• Do not allow the engine oil to get into the cartridge, it

will adversely affect the DCA concentration level.
6. Install the new cartridge on the header until the cartridge seal
contacts the seal surface of the header and then, turn the cartridge
an additional ½ to ¾ turn by hand.
• Do not over tighten the cartridge or damage may result to the

cartridge seal or threads.
7. After replacing the cartridge, turn shut off valve (1), located on the
left side of the engine, to the ON position and reinstall the radiator
cap.Start the engine and idle it for a few minutes.
8. Check the filter for possible coolant leakage.
WA900-3LC 3-75
MAINTENANCE

Maintenance for every 50, 100, 250, 500 and 1000 hours should be carried out at the same time.
CHANGING HYDRAULIC OIL AND FILTER ELEMENT

changing. When removing the oil filler cap, turn it slowly to
release the internal pressure, then remove it carefully.
Oil catch container........................ Min 725 liter (191.4 gal) capacity
Refill capacity.....................................................725 liter (191.4 gal)
1. Lower bucket to the ground, and apply parking brake, then stop the
engine.
2. Remove the bolt, then remove the cover.
3. Remove the cap of oil filler (1).
4. Remove air bleed plug (1) on filter case.
3-76 WA900-3LC
MAINTENANCE
5. Set a container to catch the oil under drain plug (3), then remove
drain plug.
6. Loosen drain valve (2), then gradually pull it out to drain the oil. After
draining the oil, close drain valve (2), then tighten drain plug (3).
This is a spring loaded assembly. Use extreme caution when

disassembling.
7. Remove mounting bolts (5) from the three filter covers (4) at the top
of the tank, then remove the covers. When doing this, the cover
may fly off because of the spring force (6), keep the cover pushed
down while removing the bolts.
8. Remove spring (6) and bypass valve (7), then remove element (8).
9. Be sure there is no foreign matter inside the tank before cleaning it.
10. Install a new element, then install bypass valve (7), spring (6),
and cover (4). If the o-ring of the cover is damaged or deteriorated,
replace it with a new part.
11. When installing the cover bolts, push the cover down and tighten
the bolts evenly.
WA900-3LC 3-77
MAINTENANCE
12. Add engine oil through oil filler port (1) to the specified level,
then install cap on filter case. For details on oil to use, see “FUEL,
COOLANT AND LUBRICANTS AMBIENT TEMPERATURE
CHART” on page 3-9..
13. Install air bleed plug (1) on filter case.
14. Check the hydraulic oil level. For details, see “EVERY 100 HOURS
OF SERVICE” on page 3-52.
15. Loosen plugs (2), (3) and (4) on the tubes at the suction side of
each piston pump. There is one plug for each pump, loosen all
three plugs. Allow all air to escape from each plug, when
non-areated oil comes out, tighten the plugs back up.
16. Check oil level and oil if necessary. Tighten the oil filler cap securely.
3-78 WA900-3LC
MAINTENANCE
17. Loosen connector (5) at the block side of the case drain hose (6) of
the piston pump. There are three case drain hoses connected to
the block, loosen only the connector of hose (6) connected to the top
of the block.
Remark
Never start the engine before the air has been completely
bled front the piston pump. If the engine is started without the
air being bled from the piston pump, the piston pump may
be damaged.
18. Run the engine at low idle and let aerated oil escape from around
the connector until no air is evident. This process may some time.
19. Tighten connector (5).
20. Check the oil level and add oil through oil filler port (1) if necessary.
For details of the oil to use, see “FUEL, COOLANT AND LUBRI-
21. Check that the hydraulic oil is at the standard level. For details, see
22. Run the engine at low idle, extend and retract the steering, bucket, and
boom cylinders 4 to 5 times. Be careful not to operate the cylinders to
the end of their stroke. Stop 100 mm (3.94 in) before the end of the
stroke.
Remark
If the engine is run immediately at high speed or the cylinder
is operated to the end of its stroke, the air inside the cylinder
will cause damage to the piston packing.
23. Next, operate the steering, bucket, and boom cylinders to the end
of their stroke 3 to 4 times, then stop the engine and loosen air
bleed plug (1) to bleed the air from the hydraulic tank. After
bleeding the air, tighten plug again.
24. Check the hydraulic oil level and add oil if needed. For details, see
25. Next, increase the engine speed and repeat the procedure in Step 23 to
bleed the air. Continue this operation until no more air comes out from plug (1).
26. After completing the air bleed operation, tighten plug (1).
Plug torque.......................... 10 to 13 Nm (7 to 9 lbf-ft)
27. After completing air bleeding, lower the bucket horizontally to the ground and stop the engine.
28. Check the hydraulic oil level. For details, see “EVERY 100 HOURS OF SERVICE” on page 3-52.
29. Check for leakage of oil from the filter cover mount.
WA900-3LC 3-79
MAINTENANCE
CLEANING HYDRAULIC TANK STRAINER
When changing the oil in the hydraulic tank, drain the oil from the tank and
clean the strainer.
1. Loosen bolts (1), then remove covers (2).
2. Loosen bolts (3), then remove covers (3).
3. Loosen bolt (5), remove strainer cover (6), then remove strainer (8)
together with spring (7).
4. Remove any dirt from strainer (8), then wash in clean non-flammable
cleaning solvent. If strainer is broken, replace it. Install spring (7),
strainer (8), and cover (6). When doing this, look through the
mounting hole of cover (4) to guide the strainer assembly in place.
Remark
When installing cover (6), coat the thread of bolt (5) with thread
locker LT-2 to prevent it from coming loose. If bolt (5) comes
loose and drops out, it will be sucked into the piston pump and
will damage the pump.
Cover bolt......................................................... 88 Nm (65 lbf-ft)
5. Install covers (2 and 4). Replace the o-rings on the covers with new.
3-80 WA900-3LC
MAINTENANCE
REPLACING HYDRAULIC TANK VENT ELEMENT

changing the oil.
When removing the oil filler cap, turn it slowly to release the
internal pressure, then remove it carefully.
1. Remove the cap of oil filler (A).
2. Remove the snap ring (1) on vent (B), then remove the vent cap (2).
3. Replace the filter element (3) with a new part. Install new o-ring (4),
then install the filter element (3), cap (2) and snap ring (1). Tighten the
oil filler cap.
Remark
It is possible to replace the element with the breather installed
in the tank. However, if the vent is removed, do not wrap the
taper thread of the vent with seal tape when assembling again,
be careful not to over tighten.
WA900-3LC 3-81
MAINTENANCE
CHANGING AXLE OIL
ignition key.
The oil is at a high temperature after the machine has been
operated wait for the temperature to go down before starting
this operation.
Oil catch container.......... Min 725 liter (191 gal) capacity
Refill capacity.......................................... 360 liter (95 gal)
4. Remove front oil filler plugs (1), then remove drain plugs (2) to
drain the oil.
3-82 WA900-3LC
MAINTENANCE
5. Remove rear oil filler plug (1), then remove drain plug (2) to drain
the oil.
6. Remove drain plug (3) to drain the oil.
7. Stop the machine so the drain plug (4) on the final drive is at the
bottom. Remove oil filler plug (5) and drain plug (4), and install
the tool in the hole (4) then drain the oil. After draining the oil,
clean drain plugs (2, 3, and 4), then re-install them.
8. Add oil to the specified level through the oil filler ports (1 and 5) of the
axle housing and left and right final drives. For details of the oil to use,
see “FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPER-
ATURE CHART” on page 3-9.
9. After adding oil, check that the oil is at the specified level. For details,
see “WHEN REQUIRED” on page 3-24.
Remark
For operations where the brake is used frequently, change the
axle oil at shorter intervals.
WA900-3LC 3-83
MAINTENANCE
REPLACING AIR CONDITIONER CAB FILTER

1. Remove the recirculation air filters (1) in the same way as when clean-
ing, and replace them with new parts. For details, see “AIR CONDI-
TIONER RECIRCULATION FILTER” on page 3-57.
2. Remove the fresh air filter (2) in the same way as when cleaning, and
replace it with a new part. For details, see “AIR CONDITIONER
FRESH AIR FILTER” on page 3-55.
CLEANING PPC CIRCUIT STRAINER

1. Remove three bolts (1) of the PPC circuit strainer.
2. Remove the strainer case (2) and pull out the strainer (3), then
wash the strainer with clean non-flammable cleaning solvent.
3. Install the strainer (3) with new o-ring (4) in the strainer case (2)
with new o-ring (5), and install it with bolts (1).
4. Operate the bucket control lever in the TILT position and the boom
control lever in the FLOAT position, when the cylinder reaches the
end of its stroke, hold it there for one minute.
5. Operate the bucket control lever in the DUMP position and the boom
control lever in the RAISE position, when the cylinder reaches the end
of its stroke, hold it there for one minute.
6. Bleed the air from the hydraulic circuit. For details, see “WHEN
REQUIRED” on page 3-24.For details of the procedure for bleeding
air from the hydraulic circuit, contact your distributor.
3-84 WA900-3LC
MAINTENANCE
CHECKING WEAR ON BRAKE DISCS
Stop the vehicle on level ground and put blocks under the wheels before checking the wear on the brake
discs.
Check Items
Brake oil pressure: Start engine, then check the brake oil pressure caution lamp, centralized warning lamp and the warning
buzzer is not sounding intermittently.
Check Method
1. Remove plug (1).
2. Depress the brake pedal to the stroke end.
3. Measure depth (A) of the spring guide below the end of the housing
with slide calipers (2).
• Keep the brake pedal depressed during measurement.
Wear limit (A).................................. 46.3 mm (1.8 in)
(A), new machine......40.7 ± 1.4 mm (1.6 ±. 0.055 in)
• If the disc wear approaches the wear limit, check the condition
frequently, regardless of the maintenance interval.
• If the disc wear exceeds the wear limit, please contact your
distributor for check and maintenance.
WA900-3LC 3-85
MAINTENANCE
CHECKING ALTERNATOR AND STARTER MOTOR
The brushes may be worn, or the bearing may have run out of grease, contact your distributor for inspection or repair. If the
engine is started frequently, carry out inspection every 1000 hours.
CHECKING ENGINE VALVE CLEARANCE

A special tool is required for removing and adjusting these parts, contact your distributor for service.
CHECKING TURBOCHARGER
If there is carbon or oil sludge stuck to the blower impeller, it will lower the performance of the turbocharger or cause it to fail,
contact your distributor to carry out the cleaning procedures.
CHECKING PLAY OF TURBOCHARGER ROTOR SHAFT

Contact your distributor to check the turbocharger rotor.
CHECKING ACCUMULATOR
Checking the gas pressure in the accumulator as follows:
1. Stop the machine on level ground (A) and apply the parking brake.
2. Raise the work equipment to the maximum height (B), then place the
lift boom control lever at HOLD.
3. Leave the work equipment in this position, and stop the engine.
4. Confirm that it is safe around the machine, then set the boom in
FLOAT and lower the work equipment to a position 1 m (3.28 ft) (C)
from the ground.
5. When the work equipment reaches a position 1 m (3.28 ft) from the ground, move the boom control lever to LOWER, and
lower the work equipment slowly to the ground.
If the work equipment stops moving during checking operations, the gas pressure may be below the service limit 7 kg/cm²
(99 psi), contact your distributor to have the gas pressure measured or re-charged. Carry out the checks within 5 minutes of
stopping the engine. If the machine is left with the engine stopped, the accumulator pressure will drop and it will be impossible
to carry out the check.
Gas pressure service limit......... 7 kg/cm² (99 psi)
3-86 WA900-3LC
MAINTENANCE

Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours should be carried out at the same time:
CHECKING WATER PUMP

Check for play in the pulley, oil leakage, water leakage, or plugged vent hole. If any abnormality is found, contact your
distributor for repair or replacement.
CHECKING ENGINE VIBRATION DAMPER

Check for damper fluid leakage, dent or wobble. If there is any abnormality, contact your distributor for repair.
CHECKING FAN AND TENSIONER PULLEY

Check the pulley to see if there is any grease leaking. If any abnormality is found, contact your distributor to repair or
replace it.
WA900-3LC 3-87
MAINTENANCE
MEMORANDUM
3-88 WA900-3LC
4SPECIFICATIONS
WA900-3LC 4-1
SPECIFICATIONS
SPECIFICATIONS
GENERAL
Standard Lift Boom High Lift Boom

WA900-3LC
13 m³ (17 yd³) Bucket 11.5 m³ (15 yd³) Bucket
Normal bucket load 23400 kg (51597 lb) 20700 kg (45636 lb)
1st 7.0 km/h (4.3 mph) 7.0 km/h (4.3 mph)
Forward 2nd 12.3 km/h (7.6 mph) 12.3 km/h (7.6 mph)
3rd 28.0 km/h (17.4 mph) 28.0 km/h (17.4 mph)

PERFORMANCE
• Travel speed
1st 7.1 km/h (4.4 mph) 7.1 km/h (4.4 mph)
Reverse 2nd 12.4 km/h (7.7 mph) 12.4 km/h (7.7 mph)
3rd 28.3 km/h (17.6 mph) 28.3 km/h (17.6 mph)
• Maximum rim pull 60000 kgf (588000 N) 60000 kgf (588000 N)
• Minimum Outside of chassis 11065 mm (435.6 in) 11150 mm (438.9 in)

turning radius Center of outside tire 9200 mm (362 in) 9200 mm (362 in)
Operating weight
Includes: Operator, rated capacities of
fuel, lubricants and coolant,
WEIGHT
102880 kg 103310 kg
standard tires and rims, standard
(226690 lb) (227760 lb)
lift boom with bucket, ROPS
canopy, steel cab, and other
standard attachments
Model Komatsu SAA12V140Z E2
SAEJ1349 636 kW (853 hp) @ 2000 rpm

Flywheel horsepower
DIN 6270 637 kW (865 PS) @ 2000 rpm
ENGINE
Maximum torque 4090 NCm (417 kgfCm) @ 1400 rpm
Starter motor 24V 11kW
Alternator 24V 75A
Battery 12V 200aH x 4 (N200)
4-2 WA900-3LC
SPECIFICATIONS
MEMORANDUM
WA900-3LC 4-3
SPECIFICATIONS
MACHINE SPECIFICATIONS
Straight
Full turn,40°
4-4 WA900-3LC
SPECIFICATIONS
Standard Lift Boom High Lift Boom

Description
mm in mm in
A Wheel base 5450 mm 214.6 in 5450 mm 214.6 in
B Center hinge pivot to front wheel 2600 mm 102.4 in 2600 mm 102.4 in
C Center hinge pivot to rear wheel 2850 mm 112.2 in 2850 mm 112.2 in
D Minimum ground clearance 550 mm 21.6 in 550 mm 21.6 in
E Overall length of machine, bucket on ground 14430 mm 568.1 in 14935 mm 588.0 in
F Overall length of machine, bucket at carry 14065 mm 553.5 in 14780 mm 581.9 in
G Front wheel to edge of bucket 5325 mm 209.6 in 5830 mm 229.5 in
H Rear wheels to rear of machine 3655 mm 143.9 in 3655 mm 143.9 in
I Hitch (tow pin) height 1390 mm 54.7 in 1390 mm 54.7 in
J Exhaust stacks to ground level 5130 mm 201.9 in 5130 mm 201.9 in
K ROPS to ground level 5275 mm 207.7 in 5275 mm 207.7 in
L Width over tires 4585 mm 180.5 in 4585 mm 180.5 in
M Center lines of tires 3350 mm 131.9 in 3350 mm 131.9 in
N Width of bucket over sweeper wings 5045 mm 198.6 in 5045 mm 198.6 in
O Width of bucket over side edges 4815 mm 189.6 in 4815 mm 189.6 in
P Digging depth at 0° 50 mm 2.0 in 50 mm 2.0 in
Q Digging depth at 10° 585 mm 23.0 in 550 mm 21.6 in
R Bucket hinge pin at carry position 800 mm 31.5 in 800 mm 31.5 in
S Operating height fully raised, 60° rollback 9680 mm 381.1 in 9875 mm 388.8 in
T Height at hinge pin fully raised 6960 mm 274.0 in 7445 mm 293.1 in
U Dump clearance at maximum height, 45° dump 4715 mm 185.6 in 5330 mm 209.8 in
V Reach at maximum height, 45° dump 2450 mm 96.5 in 2230 mm 87.8 in
Turning radius outside corner of bucket 11065 mm 435.6 in 11150 mm 439.0 in
Straight ➞ 66140 kg 145815 lb 62540 kg 137880 lb

Static tipping loads
Full turn, 40° 58200 kg 128310 lb 55030 kg 121320 lb
Breakout force 665 kN 149690 lb 703 kN 158070 lb
With 45/65-45 58PR L-5 Tires
WA900-3LC 4-5
SPECIFICATIONS
MEMORANDUM
4-6 WA900-3LC
5OPTIONS, ATTACHMENTS
WA900-3LC 5-1
OPTIONAL PARTS AND ATTACHMENTS
Name Specification, use

Bucket for standard boom 13 m³ (17 yd³) spade nose rock
Bucket for high lift boom 11.5 m³ (15 yd³) spade nose rock
Bucket for standard lift boom, light material 12.3 m³ (16 yd ³) spade nose rock - 1600 kg/m³ (2700 lb/yd³)
Bucket teeth Hensley Bladesaver II System
High lift boom Optimum for loading 120 ton class dump truck
Mesh chain Tire protector
• Additional work lamps - 2 x front, 2 x side, 2 x rear and 1 left

step with timer
• Lincoln auto grease system

• Auto shift control
• Buckets as described above
• Ground level engine shut off switch
• High lift boom
• Radio - AM/FM with cassette stereo
• Rims and tires - various
• Wiggins fast fill coupler for fuel
5-2 WA900-3LC
SELECTING BUCKETS AND TIRES
Select the most suitable bucket and tires for the type of work and the ground conditions on the job site. Contact your tire
distributor for your specific application.
13 m³ (17 yd³) Spade Nose Bucket - Standard Lift Boom

11 m³ (15 yd³) Spade Nose Bucket - High Lift Boom
Type of work Ground conditions Tires

General ground conditions
• Loading materials and blasted rock 45/65-45 58PR L-5
Hard ground

45/65-45 58PR L-5
Hard ground
• Loading blasted rock
Ground with many boulders 45/65-45 58PR L-5
Use tire chains as protectors
Soft ground with many boulders

45/65-45 58PR L-5
Hard ground
• Loading and carrying blasted rock Ground with many rocks

45/65-45 58PR L-5
Soft ground with many rocks
Use tire chains as protectors
Soft ground
Contact your distributor Contact your distributor 45/65-45 58PR L-5
12.3 m³ (16 yd³) Spade Nose Bucket - High Lift Boom, Light Material
Type of work Ground conditions Tires
• Loading light material - < 1600 kg/

Contact your distributor 45/64-R45 XLDD2
m³ (2700 lb/yd³)
Contact your distributor Contact your distributor 45/64-R45 XLDD2
The speed display differs according to the tire size, so when changing to optional tires, contact your distributor.
On job sites where there are many boulders or sharp rocks, please install tire protectors (mesh chain). Check the chain for cuts
or slack before starting operations. Be careful not to let the tires or chains slip during operations.
WA900-3LC 5-3
AUTO GREASING SYSTEM
GENERAL
1. Check for grease in the grease pump case (1). If there is not sufficient
amount of grease, install a new grease pail.
2. Be sure the grease does not leak from the piping between the pail or
grease pump case (1) and follower plate (2).
Remark
If follower plate (2) is not used, the pump (3) cannot draw up the
grease even if there is sufficient grease in the pail. Do not
remove the follower plate.
3. Turn the ignition switch ON and check the lamp (4) on the monitor
panel.
Lighting: Normal
Flashing: There is not a sufficient amount of grease in the grease pump. If

the lamp still flashes after grease pump is filled, consult your
distributor.
METHOD OF OPERATING
1. If the ignition switch is turned ON, this system automatically starts the
operation.
2. If the auto greasing switch (1) is pressed, the grease pump will operate,
regardless of the time count. The grease pump operates only while the
auto greasing switch is pressed and held on. The pump stops
immediately when the switch is released. This switch is mainly used to
check the operation of the grease pump or to supply additional grease
when needed.
5-4 WA900-3LC
PRECAUTIONS WHEN HANDLING
INJECTOR DISCHARGE ADJUSTMENT
Adjust all the injectors to the maximum discharge. Loosen lock nut (2) and
turn adjustment screw (3) counterclockwise to increase amount of grease
discharged.
BLEEDING AIR FROM MAIN LINE
Loosen the plugs installed on each injector to bleed air from the main
piping. This work should be carry out by two persons. Start bleeding at the
injector nearest to the grease pump, then bleed the other injectors in order
(Rear frame ➱ Front frame ➱ Boom ➱ Bellcrank).
This work should be performed by two persons.
1. One person removes plug (4) from one injector, then waits there. This
plug is installed in the manifold end of each injector. If air must be
bled from the main piping, remove this plug.
2. The other person presses the auto greasing start switch to start the
grease pump.
3. Discharge the grease containing air (milky white in most cases) from
the injector. If normal grease comes out, stop the grease pump.
4. Tighten plug (4) on the injector to prevent the grease from leaking out. It is impossible to see if the air has been bled by
simply checking the pressure gauge. Even if air is mixed in the grease, the auto grease system operates since the discharge
pressure of the grease pump is high. To see if the greasing system is working normally, check to be sure the grease pump
is balanced and stops in the specified operating time, 60 seconds.
WA900-3LC 5-5
BLEEDING AIR FROM PRESSURE SWITCH
1. Open transmission inspection cover (5) at the rear of the cab.
2. One person should remove the pressure switch (7) from block (6a),
and remain there. The other person presses the auto greasing switch to
start the grease pump.
3. Discharge the grease containing air (milky white in most cases) from
the block (6a). If normal grease comes out, stop the grease pump
operation.
4. Install pressure switch (7) to block (6a). Check to be sure grease is not
leaking.
BLEEDING AIR FROM SUPPLY LINE
1. One person should remove the supply line pressure gauge (8) from
block (6b), then remain there.
2. The other person presses the auto greasing switch to start the grease
pumping.
3. Discharge the grease containing air, milky white in most cases, from
the block (6b). If normal grease comes out, stop the grease pump.
4. Install pressure gauge (8) on block (6b). Check to be sure grease is not
leaking.
Remark
If air is left in the circuit, the grease pressure will not rise to the
specified level or will take a long time to rise to the specified
level and the injector will not work normally.
FILLING LINES, INJECTOR TO PIN, WITH GREASE
Remove cap (11) of filler fitting (10) of injector (9), then fill the all branch
lines with grease by using a hand air powered grease gun.
5-6 WA900-3LC
CHECK SUPPLY LINE PRESSURE
1. Check grease pump pressure gauge (12).
Normal value .................................................. 21 kg/cm² (298 psi)
2. Check supply grease line pressure gauge (13).
Normal value .............................................. 210 kg/cm² (2982 psi)
CHECK OPERATION OF INJECTOR
1. Turn the auto greasing switch ON and check the indicator pin (14) of
injector (SL-1, SL-11), be sure it is operating normally.
WA900-3LC 5-7
ADJUSTMENT OF GREASING RATE AND INJECTOR
Adjust the injector to change the greasing rate for 0 to 30 hours (1st step), 30 to 150 hours (2nd step) and after 150 hours after
the auto greasing system is installed. Set the interval to 11.25 minutes.
Up to 30 Hours Up to 150 Hours After 150 Hours

1st step 2nd step 3rd step
Interval 11.25 min. 11.25 min. 11.25 min.

Injector
Injector Adjustment of
Greasing point cc/hr cc/hr cc/hr Adjustment of injector
adjustment injector
SL-11 1 Bucket hinge (Right and left) 49.2 Open fully 49.2 Keep at position for 1st step. 49.2 Keep at position for 2nd step.
Open one fully. Close one to Close one by 5 turns from full.
2 Front bucket link 15.6 Open fully 7.8 3.9
minimum. Close one to minimum.
SL-1
3 Rear bucket link 15.6 Open fully 15.6 Keep at position for first step. 15.6 Keep at position for 2nd step.
Close by 2.5 turns from

SL-11 4 Bucket cylinder rod 7.8 Open fully 3.9 Close by 5 turns from full. 1.95
position for 2nd step.

5 Bucket cylinder bottom 7.8 Open fully 3.9 Close by 5 turns from full. 1.95
position for 2nd step.
6 Bellcrank center 15.6 Open fully 7.8 3.9
7 Boom cylinder rod (Both) 7.8 Open fully 3.9 Close by 5 turns from full. 3.9 Keep at position for 2nd step.
8 Boom cylinder head (Both) 7.8 Open fully 3.9 Close by 5 turns from full. 3.9 Keep at position for 2nd step.
9 Boom pivot (Both) 15.6 Open fully 15.6 Keep at position for first step. 15.6 Keep at position for 2nd step.
Close by 2.5 turns from posi-

10 Center hinge pin (Upper) 7.8 Open fully 3.9 Close by 5 turns from full. 1.95
tion for 2nd step.

11 Steering cylinder head (Both) 7.8 Open fully 3.9 Close by 5 turns from full. 1.95
posi-tion for 2nd step.

SL-1 12 Center support 7.8 Open fully 3.9 Close by 5 turns from full. 1.95

13 Center hinge pin (Lower) 7.8 Open fully 3.9 Close by 5 turns from full. 1.95
14 Rear axle support (Front) 15.6 Open fully 7.8 3.9
Close by 3 turns from position

15 Transmission mount support 7.8 Open fully 3.9 Close by 5 turns from full. 1.56
for 2nd step.
16 Rear axle support (Cover) 15.6 Open fully 7.8 3.9
17 Rear axle support (top) 15.6 Open fully 7.8 3.9

18 Steering cylinder rod (Both) 7.8 Open fully 3.9 Close by 5 turns from full. 1.95
The injector turns by 10 turns between the full minimum opening positions.
5-8 WA900-3LC
Greasing points, Front frame and loader linkage
1. Bucket hinge 4. Bucket cylinder rod
2. Bucket link (front) 6. Tilt lever (center)
3. Bucket link (rear) 7. Boom cylinder rod
WA900-3LC 5-9
Greasing points, Frames
5. Bucket cylinder bottom 13. Center hinge pin (lower)
8. Boom cylinder bottom 14. Rear axle support (front)
9. Boom pivot 15. Transmission mount support

10. Center hinge pin (upper) 16. Rear axle support (cover)
11. Steering cylinder bottom 17. Rear axle support (top)
12. Center support 18. Steering cylinder rod
5-10 WA900-3LC
ADJUSTING DISCHARGE FROM INJECTOR
SL-1 INJECTOR
1. The injector is operated by the pressure from the pump, it feeds grease
in specified quantities to the lube point.
2. To see if the injector works normally, check the operation of indicator

pin (1) on its head. If the injector is normal, the pin is retracted first. If
the pump stops and the pressure is lost, the pin returns and it is reset
for the next greasing.
3. Adjust the discharge from the injector with adjustment screw (3) on
the head.
A. To reduce the discharge, loosen lock nut (2) and turn adjustment
screw (3) clockwise. If the adjustment screw stops (at stopper),
the discharge is minimized.
B. If the adjustment screw is returned by 10 turns from the fully

tightened position (minimum discharge) as above, the discharge is
maximized (1.3 cc/st). After adjusting the discharge from the
injector, be sure to tighten lock nut (2).
4. Although the injector can be overhauled and repaired, replace it with a spare one, if possible,
when problems occur.
• Loosen lock nut (2) and turn adjustment screw (3) to adjust the discharge of grease.
Discharge/time
Turn clockwise to stopper 0.13 cc (Min)
Turn counterclockwise by 10 turns from

1.30 cc (Max)
above position
• One turn between the max and minimum positions changes the discharge by 0.13 cc. After
adjusting the discharge, be sure to tighten lock nut (2).
WA900-3LC 5-11
SL-11 INJECTOR
1. The injector is operated by the pressure from the pump it feeds grease
in a specified quantity to the bearings.
2. To see if the injector works, check the operation of indicator pin (4) on
its head. If the injector is normal, the pin will retract first. If the pump
stops and the pressure is lost, the pin returns and it is reset for the next
greasing.
3. Adjust the discharge with adjustment screw (6) on the head.
4. To reduce the discharge, loosen lock nut (5) and turn adjustment screw
clockwise. If the adjustment screw stops (at the stopper), the discharge
is minimized.
5. If the adjustment screw is returned by 10 turns from the fully tightened

position (minimum discharge) as above, the discharge is maximized
(8.2 cc/st). After adjusting the discharge from the injector, be sure to
tighten lock nut.
6. Although the injector can be overhauled and repaired, replace it with a spare one, if possible, when problems occur.
• Discharge adjusting procedure for large sized injector, SL-11. Added to bucket pin. Loosen lock nut (5) and turn
adjustment screw (6) to adjust the discharge of grease made each time.
Discharge/time
Turn clockwise to stopper, min. discharge 0.82 cc
Turn counterclockwise by 10 turns from above position,

8.2 cc
max. discharge
• One turn between the max and minimum positions changes the discharge by 0.82 cc. After adjusting the discharge, be
sure to tighten the lock nut.
METHOD OF SETTING TIMER

• The timer is installed to control the greasing interval of the auto grease system.
• The timer is installed in box (1) at the rear of the operators seat.
• The greasing interval can be changed freely according to the following table with the blue dial on the timer. The set
interval has an error of about ±15%, however for both stopping and starting.
5-12 WA900-3LC
Example: When timer is set to 11.25 minutes
ADJUSTMENT OF GREASING INTERVAL
Timer box (1) is in the position shown at right.
• Power supply for timer
Even after the ignition switch is turned off, both interval time and
operating time are stored in this circuit board by the capacitor for
about five days, the next operation starts under the condition when the
power was turned off the previous time. If the power is kept turned off
for more than five days, the memory is canceled.
ADJUSTING INTERVAL TIME, BLUE DIAL
• Open the door at the lower rear of the cab, then open the timer box.
Turn the dial shown at right to adjust the interval time and operating
time. To adjust the interval time, turn the blue rotary switch (1)
according to the following table.
1. Set the blue dial to division 3 after the auto grease system is installed.
Table
Position of switch 1 2 3 4 5 6 7 8 9
Greasing interval,
3.75 7.5 11.25 15 18.75 22.5 28.25 30 33.75
minutes
Position of switch A B C D E F
Greasing interval,
37.5 41.25 45 48.75 52.5 56.25
minutes
WA900-3LC 5-13
ADJUSTING OPERATING TIME, RED DIAL
To adjust the operating time, turn red rotary switch (1) according to the
following table. Normally, fix this dial to 8 (60 seconds).
1. Set the red dial to division 8, for normal operation.
2. When greasing is finished and the greasing pump is balanced, the

greasing pump stops even within the specified operating time limit
(60 sec).
Table
Position of switch 1 2 3 4 5 6 7 8 9
Pump operating time,
7.5 15 22.5 30 37.5 45 52.5 60 67.5
seconds
Position of switch A B C D E F
Pump operating time,

75 82.5 90 97.5 105 112.5
seconds
5-14 WA900-3LC
DataKom Publishing Division
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications PROPOSAL FOR MANUAL OR CSS REVISION
Fax No. (847) 970-4186
DATE: FOR INTERNAL USE ONLY -- No. PMR
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MANUAL DESCRIPTION: CSS PROGRAM - e.g: Lookup, Parts or Service
MANUAL OR CSS CD NO: CSS PROGRAM RELEASE VERSION:
MANUAL OR CSS CD ISSUE DATE: CSS BOOK PUBLISHER:
BOOK DESCRIPTION
MACHINE MODEL & S/N:
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Attach photo or sketch.

If more space is needed, use another sheet.
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WA900-3LC PALA Operacion y Mtto.

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CEAM004002

Operation & Maintenance

SERIAL NUMBERS WA900-3LC - A50001 and UP

September 2002 Copyright 2002 Komatsu

EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)

KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS

ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT):

KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSÉQUENTS.

CEKQ000600 - Komatsu America International Company 12/99

IMPORTANT ENGINE INFORMATION

SYSTÈME DE ENGINE FAMILY DISPLACEMENT LITERS

VITESSE STATIQUE IDLE SPEED RPM FAMILY EMISSION LIMIT

RÉGLAGE DE L’ALLUMAGE - _____________________________________________ KOMATSU LTD.

ENGINE DATAPLATE - ENGLISH / FRENCH

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

OPERATION AND MAINTENANCE MANUAL:

Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT70-1

WA900-3 pubinfok.fm 9/6/02

STREET ADDRESS ORDER DATE

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

KDC91E 072199 CURRENT PRICES WILL BE CHARGED

Safety precautions are described in SAFETY section 1. ★

• Digging operations • Pushing operations

For details on operating procedures, see “OPERATION” on page 2-1

During breaking in:

PLATE LOCATIONS AND TABLE TO ENTER PIN AND DISTRIBUTOR

ENGINE SERIAL NUMBER PLATE

Machine serial No.:

Engine serial No.:

Service personnel for your machine:

GENERAL PRECAUTIONS AND SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

GUIDES TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

OPTIONAL PARTS AND ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

GENERAL SAFETY RULES

Always perform a pre-operational check on your machine before operating it.

Have guards or covers repaired immediately if they are damaged.

Never remove any safety features. Always keep them in good

Safety lock lever: See “PARKING THE MACHINE” on page 2-101.

Seat belt: See “SEAT BELT” on page 2-79.

CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT

Check to be sure all personal protective equipment are in good condition

Work equipment posture: See “PARKING THE MACHINE” on page 2-101.

MOUNTING AND DISMOUNTING

FIRE PREVENTION FOR FUEL AND OIL

• Keep any open flames away from flammable fluids.

PRECAUTIONS WHEN WORKING AROUND HIGH TEMPERATURES

To prevent hot coolant from spurting out and burning you:

• Turn the engine off.

To prevent hot oil from spurting out and burning you:

• Never use compressed air for cleaning.

CRUSH OR PINCH POINT PREVENTION

FIRE EXTINGUISHER AND FIRST AID KIT

PRECAUTIONS FOR ATTACHMENTS

PRECAUTIONS WHEN HANDLING ACCUMULATOR

CAB GLASS, WASHER FLUID AND MIRRORS

BEFORE OPERATING THE MACHINE

BEFORE STARTING YOUR MACHINE

IN THE OPERATOR’S CAB

If you must travel continuously, consult your distributor first.

Do not pump the brake pedal repeatedly unless necessary.

OVERHEAD HIGH VOLTAGE CABLES