Professional Documents
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Wa1200-3 - Mom
Wa1200-3 - Mom
WA1200-3
WHEEL LOADER
SERIAL NUMBERS WA1200-3 50001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
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 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, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
This manual provides rules and guidelines which will help you use this machine safely and
effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been
lost or has become dirty and can not be read, request a replacement manual from Komatsu or your
Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners.
Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available
information of your machine or for questions regarding information in this manual.
This manual may contain attachments and optional equipment that are not available in your area.
Consult Komatsu or your Komatsu distributor for those items you may require.
WARNING
‡ Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.
‡ Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
‡ Some actions involved in operation and maintenance of the machine can cause a serious accident,
if they are not done in a 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 delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and specifications
that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your
Komatsu distributor before operating the machine.
‡ The description of safety is given in SAFETY INFORMATION on page 0-4 and in SAFETY from page
1-1.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State
of California to cause cancer, birth
defects, and other reproductive
harm.
0-1
1. FOREWORD
0-2
1. FOREWORD
0-3
2. SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and
affixed to the machine to give explanations of situations involving potential hazards and of the methods
of avoiding such situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that
may lead to personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential
level of hazard.
DANGER – Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury. This signal word is to be limited to most extreme
situations.
WARNING – Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
WARNING
To avoid hitting unlocked operation levers, lower equipment to
ground and move SAFETY LOCK LEVER to LOCK position before
starting up from operator’s seat.
Sudden and unwanted machine movement can cause serious
injury or death.
NOTICE – This word is used for precautions that must be taken to avoid actions which
could shorten the life of the machine.
0-4
2. SAFETY INFORMATION
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot
when carrying out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using words” and “Safety labels using pictograms” to indicate safety
procedures.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore, the safety messages 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, it is
your responsibility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest
information available at that time. Continuing improvements in the design of this machine can lead to
changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu
distributor for the latest available information of your machine or for questions regarding information
in this manual.
0-5
3. INTRODUCTION
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the
operator’s cab.
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 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 circumstances.
0-6
4. LOCATION OF PLATES, TABLE TO ENTER
SERIAL NO. AND DISTRIBUTOR
When requesting service or ordering replacement parts, please inform your Komatsu distributor of
the following items.
0-7
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Distributor name:
Address: Phone:
REMARKS
0-8
5. CONTENTS
1. Foreword ............................................................................................................................................ 0- 1
3. Introduction ........................................................................................................................................ 0- 6
SAFETY
6. General precautions .......................................................................................................................... 1- 2
OPERATION
10. General view ...................................................................................................................................... 2- 2
10.1 General view of machine ........................................................................................................ 2- 2
10.2 General view of controls and gauges ................................................................................... 2- 3
0-9
5. CONTENTS
0-10
5. CONTENTS
MAINTENANCE
17. Guides to maintenance ..................................................................................................................... 3- 2
20. Use of fuel, coolant and lubricants according to ambient temperature ................................... 3- 8
21. Standard tightening torques for bolts and nuts ........................................................................... 3-12
21.1 Torque list ................................................................................................................................. 3-12
SPECIFICATIONS
25. Specifications ..................................................................................................................................... 4- 2
OPTIONS, ATTACHMENTS
26. Selecting buckets and tires .............................................................................................................. 5- 2
0-11
MEMO
0-12
SAFETY
¤ WARNING
Please be sure that you fully understand this manual and the
precautions related to safety for the machine. When operating
or servicing the machine, always follow these precautions strictly.
1-1
¤ WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.
SAFETY RULES
‡ Only trained and authorized personnel can operate and maintain the machine.
‡ Follow all safety rules, precautions and instructions when operating or performing maintenance
on the machine.
‡ If you are under the influence of alcohol or medication, your ability to safety operate or repair your
machine may be severely impaired putting yourself and everyone else on your jobsite in danger.
‡ When working with another operator or with a person on worksite traffic duty, be sure that all
personnel understand all hand signals that are to be used.
SAFETY FEATURES
‡ Be sure that all guards and covers are in their proper position. Have guards and covers repaired
immediately if they are damaged.
‡ Understand the method of use of safety features and use them properly.
‡ Never remove any safety features. Always keep them in good operating condition.
1-2
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 6. GENERAL PRECAUTIONS
1-3
¤ WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.
NO PEOPLE ON ATTACHMENTS
Never let anyone ride on the bucket or attachments. There is a hazard of falling and suffering serious
injury.
A0060760
1-4
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 6. GENERAL PRECAUTIONS
PREVENTION OF BURNS
Hot coolant
‡ To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to
a temperature where it is possible to touch the radiator cap by
hand before starting the operation. Even when the coolant has
cooled down, loosen the cap slowly to relieve the pressure
inside the radiator before removing the cap.
Hot oil
‡ To prevent burns when checking or draining the oil, wait for the
oil to cool to a temperature where it is possible to touch the
plug by hand before starting the operation. Even when the oil
has cooled down, loosen the plug slowly to relieve the internal
pressure before removing the plug.
1-5
¤ WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.
FIRE PREVENTION
‡ Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous.
To prevent fire, always observe the following:
• Do not smoke or use any flame near fuel or oil.
• Stop the engine before refueling.
• Do not leave the machine while adding fuel or oil.
• Tighten all fuel and oil caps securely.
• Do not spill fuel on overheated surfaces or on parts of the electrical system.
• Use well-ventilated areas for adding or storing oil and fuel.
• Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• When carrying out grinding or welding work on the chassis, move any flammable materials to
a safe place before starting.
• When washing parts with oil, use a non-flammable oil. Diesel oil and gasoline may catch fire,
so do not use them.
• Put greasy rags and other flammable materials into a safe container to maintain safety at the
work place.
• Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
A0055020
A0055040
‡ Fire caused by accumulation of flammable material.
Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumu-
lated or affixed around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.
1-6
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 6. GENERAL PRECAUTIONS
UNAUTHORIZED MODIFICATION
Any modification mode without authorization from Komatsu can create hazards.
Before making a modification, consult your Komatsu distributor.
‡ Komatsu will not be responsible for any injuries, accidents, or product failures resulting from
modifications made without authorization from Komatsu.
1-7
¤ WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.
SAFETY AT WORKSITE
Before starting operations, thoroughly check the area for any
unusual conditions that could be dangerous.
‡ When carrying out operations near combustable materials such
as thatched roofs, dry leaves or dry grass, there is a hazard of
fire, so be careful when operating.
‡ Check the terrain and condition of the ground at the worksite,
and determine the safest method of operation. Do not carry out
operations at places where there is a hazard of landslides or
falling rocks.
AE060770
‡ If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify their
locations. Be careful not to sever or damage any of these lines.
‡ Take necessary measures to prevent any unauthorized person
from entering the operating area.
‡ When traveling or operating in shallow water or on soft ground,
check the shape and condition of the bedrock, and the depth
and speed of flow of the water before starting operations.
‡ Set and maintain the haul load on the jobsites so that the
machine can always travel safely.
1-8
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 6. GENERAL PRECAUTIONS
voltage
rious burns or even death. Always maintain 100 • 200 V 2m
Low
a safe distance (see the table on the right)
between the machine and the electric cable. 6,600 V 2m
Check with the local power company about 22,000 V 3m
Very high voltage
A0055060
1-9
¤ WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.
A0055060
1-10
7. PRECAUTIONS FOR ¤ WARNING: Failure to follow these safety
OPERATION precautions may lead to a serious accident.
DO NOT operate
When this plate is not being used
keep it in the storage compartment.
09963-03000
1-11
¤ WARNING: For reasons of safety, always
7. PRECAUTIONS FOR OPERATION follow these safety precautions.
1-12
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 7. PRECAUTIONS FOR OPERATION
1-13
¤ WARNING: For reasons of safety, always
7. PRECAUTIONS FOR OPERATION follow these safety precautions.
PROHIBITED OPERATIONS
‡ It is dangerous to excavate the bottom of a rock face. Never do
this.
‡ It is dangerous to use the bucket or lift arm for crane operations,
so do not carry out such operations.
‡ Do not pass the bucket over the head of other workers or over
the operator’s seat of dump trucks or other hauling equipment.
The load may spill or the bucket may hit the dump truck or
worker and cause serious personal injury or damage.
1-14
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 7. PRECAUTIONS FOR OPERATION
1-15
¤ WARNING: For reasons of safety, always
7. PRECAUTIONS FOR OPERATION follow these safety precautions.
PARKING MACHINE
‡ Park the machine on firm, level ground.
‡ Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
1-16
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 7. PRECAUTIONS FOR OPERATION
7.3 TRANSPORTATION
The machine can be divided into parts for transportation, so when transporting the machine, please
contact your Komatsu distributor to have the work carried out.
LOADING AND UNLOADING
When loading or unloading the machine, mistaken operation may bring the hazard of the machine
tipping over or falling, so particular care is necessary. Always do as follows.
‡ Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge
of the road or cliff.
‡ Always use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough
to provide a safe loading slope. Take suitable steps to prevent the ramps from moving out of
position or coming off.
‡ Be sure the ramp surface is clean and free of grease, oil, ice and loose materials. Remove dirt from
machine-tracks. On a rainy day, in particular, take extremely careful since the ramp surface is
slippery.
‡ Run the engine at low idling and operate slowly at low speed.
‡ Never correct your steering on the ramps. There is danger that the machine may turn over. If
necessary, drive off the ramps, correct the direction, then enter the ramps again.
‡ When loading or unloading to an embankment or platform, make sure that it has suitable width,
strength, and grade.
‡ For machines equipped with a cab, always lock the door after loading the machine. If this is not
done, the door may suddenly open during transportation.
CORRECT
SHIPPING
When shipping the machine on a trailer, do as follows.
‡ Investigate all state and local laws governing the weight, width, and length of a load. If necessary,
disassemble the work equipment. The width, height and weight of the load differ according to the
work equipment, so take this into account when determining the shipping route.
‡ When passing over bridges or structures on private land, check first that the structure is strong
enough to support the weight of the machine. When traveling on public roads, checks first with
the relevant authorities and follow their instructions.
‡ For details of the shipping procedure, see 13. TRANSPORTATION in the OPERATION section.
1-17
¤ WARNING: For reasons of safety, always
7. PRECAUTIONS FOR OPERATION follow these safety precautions.
7.4 BATTERY
BATTERY HAZARD PREVENTION
Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which
may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe
the following precautions.
‡ Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line.
This may cause an explosion. Always check the battery electrolyte level periodically and add
distilled water to bring the electrolyte level to the UPPER LEVEL line.
‡ When working with batteries, always wear safety glasses and rubber gloves.
‡ If acid gets into your eyes, flush them immediately with large
quantities of water and seek medical attention.
‡ Flammable hydrogen gas is generated when the battery is charged, so remove the battery from
the chassis, take it to a well-ventilated place, and remove the battery caps before charging it.
1-18
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 7. PRECAUTIONS FOR OPERATION
‡ When starting from another machine, do not allow the two machines to touch.
‡ When connecting the booster cables, turn the starting switch OFF for both the normal machine
and problem machine. There is a hazard that the machine will move when the power is connected.
‡ Be sure to connect the positive + cable first when installing the booster cables. Disconnect the
ground or negative - cable (ground side) first when removing them.
‡ When removing the booster cables, be careful not to let the booster cable clips touch each other
or to let the clips touch the machine.
‡ Always wear safety goggles and rubber gloves when starting the engine with booster cables.
‡ When connecting a normal machine to a problem machine with booster cables, always use a
normal machine with the same battery voltage as the problem machine.
‡ For details of the starting procedure when using booster cables, see 16.3.3 STARTING ENGINE
WITH BOOSTER CABLE in the OPERATION section.
1-19
¤ WARNING: For reasons of safety, always
7. PRECAUTIONS FOR OPERATION follow these safety precautions.
7.5 TOWING
WHEN TOWING
Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake
in the selection or inspection of the wire rope.
When towing, always use the method given in 16.2 TOWING MACHINE in the OPERATION section.
‡ Always wear leather gloves when handling wire rope.
‡ During the towing operation, never stand between the towing machine and the machine being
towed.
1-20
8. PRECAUTIONS FOR ¤ WARNING: Failure to follow these safety
MAINTENANCE precautions may lead to a serious accident.
DO NOT operate
When this plate is not being used
keep it in the storage compartment.
09963-03000
1-21
¤ WARNING: For reasons of safety, always
8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions.
‡ Set safety lock lever 3 for the joystick lever to the LOCK
position.
1-22
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE
‡ When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts, so
be extremely careful.
A0055210
‡ Never drop or insert tools or other objects into the fan or fan
belt. Parts may break or be sent flying.
‡ Set safety lock levers 1 and 2 to the LOCK position so that the
work equipment and steering do not move.
Turn parking brake switch 3 to the ON position to prevent the
machine from moving.
PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.
A0055120
1-23
¤ WARNING: For reasons of safety, always
8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions.
A0055140
ACCUMULATOR
The accumulator is charged with high-pressure nitrogen gas.
When handling the accumulator, careless proceduremay cause an
explosion which could lead to serious injury or property damage.
For this reason, always observe the following precautions.
‡ Do not disassemble the accumulator.
‡ Do not bring it near flame or dispose of it in fire.
‡ Do not make holes in it, weld it, or use a cutting torch.
‡ Do not hit or roll the accumulator, or subject it to any impact.
‡ When disposing of the accumulator, the gas must be released.
Please contact your Komatsu distributor to have this work
performed.
PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel
into the area. If necessary, employ an observer.
ATTACHMENTS
‡ Appoinnt a leader before starting removal or installation opera-
tions for attachments.
‡ Place attachments that have been removed from the machine
in a stable condition so that thay do not fall. And take steps to
prevent unauthorized presons from entering the storage area.
A0055130
NOISE
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
When carrying out maintenance of the engine and you are exposed to noise for long periods of time,
wear ear covers or ear plugs while working.
1-24
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE
‡ If pins are hit with strong force, there is a hazard that the pin
may fly out and injure people in the surrounding area.
REPAIR WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with
a proper equipment. There is a hazard of fire or electrocution when carrying out welding, so never
allow any unqualified personnel to carry out welding.
1-25
¤ WARNING: For reasons of safety, always
8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions.
WASTE MATERIALS
To prevent pollution, pay careful attention to the method of
disposing of waste materials.
‡ Always put oil drained from your machine in containers.
Never drain oil directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
COMPRESSED AIR
‡ When carrying out cleaning with compressed air, there is a hazard of serious injury or property
damage caused by flying particles.
‡ When using compressed air to clean elements or the radiator, always wear safety goggles, dust
mask, gloves, and other protective equipment.
‡ The material of these components naturally changes over time, and repeated use causes
deterioration, wear, and fatigue. As a result, there is a hazard that these components may fail and
cause serious injury or property damage. It is difficult to judge the remaining life of these
components from external inspection or the feeling when operating, so always replace them at
the specified interval.
‡ Replace or repair safety critical parts if any defect is found, even when they have not reached the
time specified interval.
1-26
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE
1-27
9. POSITION FOR ATTACHING SAFETY LABELS
Always keep these labels clean. If they are lost or damage, attach them again or 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 Komatsu distributor.
1-28
9. POSITION FOR ATTACHING SAFETY LABELS
Sudden and unwanted machine If the switch is set to RELEASE, a serious accident
could result, as this operation releases the parking brake
movement can cause serious injury or and the machine may move off suddenly.
death. Never set the switch to RELEASE except when towing a
disabled machine.
Before towing such machine, read its manual carefully
and be sure to follow the instructions given therein.
1-29
9. POSITION FOR ATTACHING SAFETY LABELS
• If necessary, lock safety bar during 8. Precautions when oil is at high temperature
servicing or maintenance.
1-30
9. POSITION FOR ATTACHING SAFETY LABELS
10. Precautions when handling battery 12. “Do not go under work equipment” sign
(09807-C1683)
11. High pressure warning 13. “Do not open when engine is running” sign
(09659-53000) (09667-03001)
Explosion hazard
• Keep away from frame.
• Do not weld or drill. CAUTION
09659-53000
1-31
9. POSITION FOR ATTACHING SAFETY LABELS
14. “Do not come near machine” sign 17. Jump start prohibited (09842-A0481)
(09812-03000) (This plate is stick on the starting motor.)
1-32
OPERATION
¤ WARNING
Before reading the OPERATION section, be sure that you
have read and understood the SAFETY section
2-1
10. GENERAL LOCATIONS
2-2
10. GENERAL VIEW
2-3
10. GENERAL VIEW
2-4
10. GENERAL VIEW
2-5
11. EXPLANATION OF COMPONENTS
The following is an explanation of the devices needed for operating the machine.
To carry out suitable operations correctly and safely, it is important to understand fully the methods
of operating the equipment and the meanings of the displays.
The machine monitor system consists of the main monitor (in front of the operator’s seat), the
monitor screen and caution display screen displayed on the CGC monitor, and the meter display (service
meter) at the rear of the work equipment control lever.
The monitor system can be divided functionally into the alarm display portions (B, E), the meter
display portions (A, F), the monitor screen (D), and the switch and indicator portion (C).
2-6
11. EXPLANATION OF COMPONENTS
CAUTION
These monitors do not guarantee the condition of the machine.
Do not simply rely on the monitor when carrying out checks before starting (daily inspection).
Always get off the machine and check each item directly.
(B, CGC monitor caution display screen E) For details, see warning display portions (11.1.1).
These consist of the central check lamp (CHECK), central warning lamp (CAUTION), emergency
steering pilot lamp, and the caution display screens shown on the CGC monitor (engine oil temperature,
engine water temperature, torque converter oil temperature, hydraulic oil temperature, front, rear brake
oil pressure caution, battery electrolyte level caution, brake fluid level caution, coolant level caution,
transmission oil filter clogging, defective charger current, voltage; for details of other display portions,
see the CGC monitor).
2-7
11. EXPLANATION OF COMPONENTS
MAIN MONITOR
1. Central check lamp (CHECK) 3. Emergency steering pilot lamp (red)
2. Central caution lamp (CAUTION)
CGC MONITOR
4. Engine oil level caution display 14. Battery electrolyte level (3) caution display
5. Engine oil pressure caution display 15. Brake oil level caution display
6. Engine water temperature caution display 16. Engine water level caution display
7. Fuel level caution display 17. Transmission oil filter clogging caution dis-
8. Torque converter oil temperature caution play
display 18. Air cleaner (1) clogging caution display
9. Hydraulic oil temperature caution display 19. Air cleaner (2) clogging caution display
10. Front brake oil pressure caution display 20. Air cleaner (3) clogging caution display
11. Rear brake oil pressure caution display 21. Air cleaner (4) clogging caution display
12. Battery electrolyte level (1) caution display 22. Battery charge voltage caution display
13. Battery electrolyte level (2) caution display
2-8
11. EXPLANATION OF COMPONENTS
MAIN MONITOR
1. CENTRAL CHECK LAMP (CHECK)
WARNING
If this monitor flashes, carry out inspection and maintenance of
the appropriate location as soon as possible.
2-9
11. EXPLANATION OF COMPONENTS
2-10
11. EXPLANATION OF COMPONENTS
CGC MONITOR
DISPLAY ITEMS (WARNING ITEMS)
The main items related to danger displayed on the CGC monitor are as shown in the table below.
If a warning display is given, take the action given on the screen.
Warning output Cansel
Display CGC Main monitor output switch Error
No. Item
range warning Screen CHECK CAUTION Yes, Code Remarks
display color lamp lamp Buzzer No No.
Below low
1 Engine oil level level Abnormal Red Flashes – – Yes C253
Below
2 Engine oil pressure specified Abnormal Red – Flashes Sounds No C143
pressure
More than
3 Engine water temperature 102°C Abnormal Red – Flashes Sounds Yes C151
Below speci- Lack of Before
fied level fuel Yellow Flashes – – Yes B@BFZK engine runs
4 Fuel level
Below speci- Lack of After
fied level fuel Yellow – Flashes – Yes b@BFZK engine runs
More than
Torque converter oil 120°C Abnormal Yellow – Flashes – Yes B@CENS
5
temperature More than
130°C Abnormal Red – Flashes Sounds Yes b@CENS
More than
6 Hydraulic oil temperature 105°C Abnormal Red – Flashes – Yes B@HANS
Less than Under ac-
14.72 MPa 2 cumulated Yellow – Flashes – Yes 2G41MB
7 Brake oil pressure (F) (150 kgf/cm , pressure
2130 lbft) Abnormal Red – Flashes Sounds No 2G42ZG
Less than Under ac-
14.72 MPa2 cumulated Yellow – Flashes – Yes 2G41MB
8 Brake oil pressure (R) 150 kg/cm , pressure
2130 lbft) Abnormal Red – Flashes Sounds No 2G43ZG
Below low
9 Battery electrolyte level (1) level Abnormal Yellow Flashes – – Yes B@GAZK
Below low
10 Battery electrolyte level (2) level Abnormal Yellow Flashes – – Yes B@GBZK
Below low
11 Battery electrolyte level (3) level Abnormal Yellow Flashes – – Yes B@GCZK
Below speci-
fied level Abnormal Yellow Flashes – – Yes B@C5ZK
12 Brake oil level
Below speci-
fied level Abnormal Red – Flashes Sounds No b@C5ZK
Below low Before
level Abnormal Yellow Flashes – – Yes B@BCZK engine runs
13 Engine water level
Below low After
level Abnormal Red – Flashes Sounds No b@BCZK engine runs
Above speci-
14 Transmission filter clogging fied pressure Abnormal Yellow Flashes – – Yes 15B0NX
Above speci-
15 Air cleaner clogging (1) fied pressure Abnormal Yellow Flashes – – Yes AA1ANX
Above speci-
16 Air cleaner clogging (2) fied pressure Abnormal Yellow Flashes – – Yes AA1BNX
Above speci-
17 Air cleaner clogging (3) fied pressure Abnormal Yellow Flashes – – Yes AA1CNS
Above speci-
18 Air cleaner clogging (4) fied pressure Abnormal Yellow Flashes – – Yes AA1DNX
Defective charge amount, When charge
19 voltage is defective Abnormal Yellow Flashes – – Yes AB00MA
If any warning item is generated, the warning screen and in-use screen are displayed in turn. If more than one
warning item has occurred, the warning screen is displayed in turn at 5-second intervals.
If the JUMP switch is pressed while the warning screen is being displayed, the in-use screen is displayed for 2
minutes. When this is done, the PAUSE switch function changes and it becomes the RESTART switch. If the RESTART
switch is pressed during the 2-minute display of the warning screen, the next screen is displayed.
It is possible to cancel the warning screen temporarily by pressing the “cancel” switch. Even if there is an
abnormality on the machine, the warning screen is canceled. When the starting switch is next turned ON, or when
the user ID is changed, if the warning screen has been canceled in this way but the abnormality has not been
removed, the warning display will appear again.
2-11
11. EXPLANATION OF COMPONENTS
2-12
11. EXPLANATION OF COMPONENTS
2-13
11. EXPLANATION OF COMPONENTS
2-14
11. EXPLANATION OF COMPONENTS
2-15
11. EXPLANATION OF COMPONENTS
‡ When the brake oil pressure goes below 14.72 MPa (150 kgf/cm2,
2130 PSI) while the machine is being operated
The title and message are displayed on the CGC monitor to
indicate an abnormality. When this happens, the title screen
turns red, the central warning lamp (CAUTION) on the main
monitor flashes, and the alarm buzzer sounds.
If this type of abnormality is displayed, stop operations imme-
diately and check the brake oil pressure system.
2-16
11. EXPLANATION OF COMPONENTS
2-17
11. EXPLANATION OF COMPONENTS
When carrying out the checks before starting (main switch ON,
engine stopped)
If the level of the oil in the brake line and cooler line is low, the
title and message are displayed on the CGC monitor as a caution.
The central check lamp (CHECK) on the main monitor will also flash.
If the lamp flashes and the message is displayed on the CGC
monitor, check the brake oil level and add oil.
In addition, check the brake system for leakage.
2-18
11. EXPLANATION OF COMPONENTS
When carrying out the checks before starting (main switch ON,
engine stopped)
If the level of the coolant in the radiator is low, the title and
message are displayed on the CGC monitor as a caution. The central
check lamp (CHECK) on the main monitor will also flash.
If the lamp flashes and the message is displayed on the CGC
monitor, check the coolant level in the radiator and add water.
Stop the machine on level ground before checking the water
level.
2-19
11. EXPLANATION OF COMPONENTS
These caution displays warn the operator that one of the four air
cleaners is clogged.
A Title screen: Yellow
B Error code: AA1ANX(18)
AA1BNX(19)
AA1CNX(20)
AA1DNX(21)
2-20
11. EXPLANATION OF COMPONENTS
2-21
11. EXPLANATION OF COMPONENTS
PILOT DISPLAY
When the starting switch is ON, the pilot display lights up when
the display items are functioning.
2-22
11. EXPLANATION OF COMPONENTS
METERS
6. SPEEDOMETER
This meter indicates the travel speed of the machine.
8. SERVICE METER
This meter shows the total hours of operation of the machine.
If the engine is running, the service meter will advance even if
the machine is not moving.
When the engine is running, display A inside the meter rotates
to show that the meter is advancing.
The meter advances by 1 for every one hour of operation,
regardless of the engine speed.
9. FUEL GAUGE
This meter is displayed on the CGC monitor and indicates the
amount of fuel in the fuel tank.
E: Tank is EMPTY (less than 550 ¬ (145.2 US gal))
F: Tank is FULL (more than 3700 ¬ (976.8 US gal))
If the yellow range lights up during operation, it means that there
is less than 1250 ¬ (330.0 US gal) of fuel left, so check and add fuel.
In this case, the central caution lamp (CAUTION) will flash.
2-23
11. EXPLANATION OF COMPONENTS
2-24
11. EXPLANATION OF COMPONENTS
11.2 SWITCHES
2-25
11. EXPLANATION OF COMPONENTS
1. STARTING SWITCH
This switch is used to start or stop the engine.
OFF: The key can be inserted and removed at this position. When
the key is turned to this position, all electric circuits are
turned off and the engine stops.
In addition, the parking brake is automatically applied.
START: This is the position for starting the engine. When starting
the engine, first turn the key to this position. The prelube
indicator will light up, prelubrication will automatically
start, and the engine will start. Return the key to the ON
position.
After lubrication, the starting motor will rotate and the
engine will start. If it is difficult to start the engine in cold
weather, turn to this position and spray ether inside the
intake manifold.
For details of the method for using ether, see “12.2.2
STARTING IN COLD WEATHER”.
REMARK
Prelube means sending grease to lubricate all parts before the
engine is cranked.
2. LAMP SWITCH
This switch is used to light up the front lamps, side clearance
lamps, tail lamps, and instrument panel.
Position a: OFF
Position b: Side clearance lamps, tail lamps, and instrument panel
light up
Position c: Front lamps light up
2-26
11. EXPLANATION OF COMPONENTS
This dial can be used to set the maximum travel speed according
to the position of the dial and the transmission speed range.
When the travel speed limit ON-OFF switch is turned ON, the
travel speed limit ON-OFF indicator lamp A lights up.
If indicator lamp A is not lighted up, the travel speed limit dial will
not work.
REMARK
Because the travel speed can be set with the travel speed limit
dial, the travel speed can be kept low with the accelerator pedal
depressed when approaching a dump truck, so operations can be
carried out easily.
2-27
11. EXPLANATION OF COMPONENTS
The drive force limit makes it possible to use the dial to change
between 20% of the drive force (minimum) and 100% of the drive
force (maximum).
REMARK
Setting the drive force with the drive force limit dial makes it
possible to prevent tire slippage by lowering the drive force before-
hand on slippery road surfaces, such as muddy ground where the
tires are likely to slip.
It is possible to change the value of the drive force according to
the conditions of the jobsite, but set the value to match the condi-
tions such as the productivity and tire slippage.
2-28
11. EXPLANATION OF COMPONENTS
This switch is used to carry out deletion when the data meas-
ured by the load meter has become unnecessary, and to return to
the display before measurement.
ON: The power for the travel speed limit mode is switched on,
and the maximum speed is set by the set position of the
travel speed limit dial.
OFF: The power for the travel speed limit mode is switched off,
and even if the travel speed limit dial is set, the maximum
speed cannot be set.
REMARK
The ON/OFF condition of the travel speed limit switch is dis-
played by the indicator lamp at the bottom of the travel speed limit
dial.
If the lamp is lighted up, the travel speed limit switch is ON.
2-29
11. EXPLANATION OF COMPONENTS
8. KICK-DOWN SWITCH
When the gear is in 2nd and switch at the top of the knob of the
lift arm control lever is pressed, the gear will shift down to 1st.
This switch is used to increase the drawbar pull in digging
operations.
REMARK
To cancel the kick-down switch, move the directional switch to
REVERSE or NEUTRAL, or shift to any position except 2nd. It is also
possible to cancel the kick-down switch by operating the parking
brake switch or by turning the starting switch OFF.
REMARK
‡ When the switch is operated, the turn signal lamp pilot lamp also
lights up.
‡ The turn signal switch does not return automatically when the
joystick steering lever is returned. Return it to the neutral posi-
tion by hand.
CAUTION
Do not continue to operate the switch when the window is fully
open or fully closed. This will cause failure of the power win-
dow.
These switches are used to open and close the windows of the
doors on both sides of the operator’s cab.
These switches can be used when the starting switch is at the ON
position.
When the window reaches the top or bottom and the window
stops moving, release the switch immediately.
2-30
11. EXPLANATION OF COMPONENTS
AE061260
REMARK
‡ The RPM SET ON-OFF switch is used only for turning the power
to the RPM set system ON or OFF. To set the engine speed, use
the RPM set IDLE UP-DOWN selector switch.
‡ This switch is a seesaw switch, so do not press it unnecessarily.
2-31
11. EXPLANATION OF COMPONENTS
Position b: Use this position when lowering the set engine speed
or when resetting the set speed after it has been
canceled with the RPM set switch.
‡ When using RPM set idling up-down switch:
Keep switch position b pressed for at least 0.5 sec to lower the
engine speed. When the engine goes down to the desired speed,
release the switch. The new speed is set and saved in memory.
REMARK
‡ Setting the engine speed by setting the RPM can prevent the
engine speed from going down more than necessary when
carrying out operations with the accelerator pedal. This im-
proves the engine acceleration and makes it possible to reduce
the cycle time.
‡ When traveling in load-and-carry operations, the travel speed is
kept constant, so operator fatigue can be reduced.
‡ When resetting the engine speed to the desired speed without
using down position b of the RPM set idling up-down selector
switch, depress the right brake to cancel the set engine speed,
then use the accelerator pedal to raise the engine speed. When
the engine rises to the desired speed, press switch position a.
The new speed is set and saved in memory.
2-32
11. EXPLANATION OF COMPONENTS
REMARK
When this switch is turned to the ON position, the turn signal
lamps and turn signal pilot lamp flash.
NOTICE
‡ Never use the parking brake switch to apply the brakes when
traveling, except in an emergency. Apply the parking brake only
after the machine has stopped.
‡ If the parking brake has been used as an emergency brake when
traveling at high speed (near the maximum speed), contact your
Komatsu distributor to have the parking brake checked for any
abnormality.
REMARK
‡ If the directional switch is set to F (FORWARD) or R (REVERSE)
with the parking brake applied, the central warning lamp will
flash and the alarm buzzer will sound.
‡ Before starting the engine, turn the parking brake switch to ON,
then turn it to OFF.
‡ The machine will not start if the directional switch is operated
with the parking brake applied.
2-33
11. EXPLANATION OF COMPONENTS
This switch is used to spray ether into the intake manifold when
the engine does not start using the engine starting procedure in
ambient temperatures of less than –10°C (14°F).
Position a: ON, ether is sprayed.
Position b: OFF, ether is not sprayed.
REMARK
When the switch is released at the ON position, it will automati-
cally return to the OFF position.
2-34
11. EXPLANATION OF COMPONENTS
Set the switch to the ON position for the side clearance lamp or
ON position for the head lamp. The front working lamp will not light
up if the switch is not at the correct position.
ON: Lights up
OFF: Goes off
Set the switch to the ON position for the side clearance lamp or
ON position for the head lamp. The rear working lamp will not light
up if the switch is not at the correct position.
2-35
11. EXPLANATION OF COMPONENTS
REMARK
For general operations, using the transmission cut-off function
reduces the rise in the brake oil temperature and torque converter
oil temperature.
2-36
11. EXPLANATION OF COMPONENTS
REMARK
‡ The step lamp switch is at the step and the top right of the
operator’s compartment. Use either of these to turn the lamp on
or off.
‡ The step lamp can be turned on or off even when the starting
switch is OFF.
Always turn this lamp off when leaving the machine.
REMARK
‡ During intermittent operation, the center and left or right wipers
may not operate together in the same cycle because of the load
on the wiper, but this is not an abnormality.
‡ The left and right wipers do not change speed even when the
front wiper switch is set to the low speed position or high speed
position, but this is not an abnormality.
2-37
11. EXPLANATION OF COMPONENTS
In the following cases, the lamp will flash at 0.5 second intervals.
‡ Empty cartridge, broken circuit
The circuit pressure when the pump is actuated does not rise to
the set pressure and cannot carry out greasing.
‡ Cut in power supply
The power supply is cut and the system cannot function.
‡ Defective release of pressure
After completion of greasing, the circuit pressure does not go
down and the plunger does not return, so the next greasing
cannot be carried out.
‡ Even when normal, during period until pressure inside the circuit
rises to set pressure
2-38
11. EXPLANATION OF COMPONENTS
REMARK
‡ The room lamp lights up even when the starting switch is OFF,
so when leaving the operator’s compartment, turn the switch to
position a (OFF) or b.
‡ When operating with the operator’s compartment door fully
open, set the switch to position a (OFF).
REMARK
This switch is installed on the inside on both sides of the radiator
guard.
Use either of the switches to turn on the lighting.
2-39
11. EXPLANATION OF COMPONENTS
2-40
11. EXPLANATION OF COMPONENTS
2-41
11. EXPLANATION OF COMPONENTS
2-42
11. EXPLANATION OF COMPONENTS
2-43
11. EXPLANATION OF COMPONENTS
REMARK
In addition to this function, this lever is also equipped with the
FNR switch, which is used to select the direction of travel of the
machine, the shift-up and shift-down switches to shift gear, and the
horn switch. For details of the various devices, see “11.2 SWITCHES”.
7. BRAKE PEDALS
WARNING
‡ When traveling downhill, always turn the transmission cut-
off switch OFF, use the brake pedal, and also use the engine
as a brake.
‡ Do not use the brake pedals repeatedly unless necessary.
‡ Do not put your foot on this pedal unless necessary.
REMARK
When using the brake and accelerator together to slow the
machine or stop it while operating the work equipment, turn the
transmission cut-off switch ON and depress the left brake pedal.
2-44
11. EXPLANATION OF COMPONENTS
8. ACCELERATOR PEDAL
This pedal controls the engine speed and output.
The engine speed can be freely controlled between low idling
and full speed.
Position b: HOLD
The bucket is kept in the same position.
Position c: DUMP
REMARK
In addition to these functions, this lever is also equipped with the
speed limit ON-OFF switch, which is installed to the top of the lever,
and the load meter cancel switch, which is installed to the side of the
lever. For details of the various devices, see “11.2 SWITCHES”.
2-45
11. EXPLANATION OF COMPONENTS
Position b: HOLD
The lift arm is kept in the same position.
Position c: LOWER
Position d: FLOAT
The lift arm moves freely under external force.
REMARK
In addition to these functions, this lever is also equipped with the
kick-down switch, which is installed to the top of the lever, and the
transmission auto shift, manual shift selector switch, which is in-
stalled to the side of the lever. For details of the various devices, see
“11.2 SWITCHES”.
2-46
11. EXPLANATION OF COMPONENTS
2. Turn the key counterclockwise and bring the rotor groove in line
with the aligning mark on the cap. Turn the cap slowly until the
“clicking” sound is made. This releases the lock and allows the
cap to be opened.
2-47
11. EXPLANATION OF COMPONENTS
2-48
11. EXPLANATION OF COMPONENTS
Fuse box I
2-49
11. EXPLANATION OF COMPONENTS
Fuse box II
0 10A Auto-greasing
E 10A Option
SLOW-BLOW FUSE
(1) 120A: Main power
(2) 80A: Battery power (starting switch, hazard)
2-50
11. EXPLANATION OF COMPONENTS
2-51
11. EXPLANATION OF COMPONENTS
2-52
11. EXPLANATION OF COMPONENTS
1. POWER SWITCH/VOLUME
Turn this knob to the right until it clicks to turn the power on.
Turn it further to increase the volume.
‡ Auto-store
If this button is pressed for at least 2 seconds during radio
reception, the system will automatically search for radio stations
within the same band and will store the frequency in the preset
memory. During this operation, the channel display on the right
side of the display will change.
This shows that the frequency is being saved to each memory
channel.
REMARK
The auto-store function cannot be used when the channel dis-
play is flashing.
When the display is flashing, the preset scan function is being
used.
‡ Preset scan
If this button is pressed for less than 2 seconds during radio
reception, the stations preset in the present reception band are
broadcast for 5 seconds each from No. 1 to No. 6.
To listen to the desired station, press the button again. After the
preset scan operation is completed, it will return to normal
broadcasting.
2-53
11. EXPLANATION OF COMPONENTS
5. LOUDNESS BUTTON
This button is used when playing at low volume. It makes it
possible to hear more easily by emphasizing the low tone when it
is felt that the low tones are weak.
Push button: Actuated (ON)
Push button again: Canceled (OFF)
‡ Correcting time
Press the button to set to the time display.
A Correcting hour: Keep the DISP button pressed and press the
bottom tuning button (H) to correct the
hour.
B Correcting minute: Keep the DISP button pressed and press the
top tuning button (M) to correct the minute.
8. CASSETTE DOOR
Set the cassette with the exposed portion of the tape on the right
side and insert it in cassette door.
2-54
11. EXPLANATION OF COMPONENTS
‡ Fast forward/rewind
If you press the button pointing in the same direction as the
arrow indicating the direction of play, the tape will be fast
forwarded; if you press the button pointing in the opposite
direction, the tape will be rewound.
To stop the tape, lightly press the button that is not locked. The
fast forward or rewind operation will be canceled.
2-55
11. EXPLANATION OF COMPONENTS
1. If you are playing a cassette, press the tape eject button to stop
the tape.
2. Select the station to be preset.
Use band selector button 1 to select MW (AM), FM1, or FM2,
then use the manual tuning button to select the frequency of the
broadcasting station.
3. Press manual memory button 2 or seek tuning button 3.
4. Press preset button 4 of the number to be preset for 2 seconds
while the frequency display is being shown on the display. (The
preset channel and frequency are displayed and the presetting
is completed).
5. Repeat Steps 2 to 4 to preset other stations.
REMARK
‡ Use Steps 2 to 4 also when changing the setting of a preset
switch to another station.
‡ When the power is disconnected, such as when the battery is
replaced, all the settings are deleted, so preset the stations
again.
2-56
11. EXPLANATION OF COMPONENTS
LISTENING TO RADIO
1. Turn the starting switch ON, then turn power switch 1 ON.
2. Set band selector button 2 to AM or FM.
3. Select the station with the preset buttons or manual tuning
button 3.
4. Adjust the volume, balance, and tone as desired.
5. When turning the radio OFF, turn power switch 1 to the left until
there is a click.
REMARK
‡ To switch to the radio when listening to a cassette, press the
cassette eject button to stop the tape.
‡ If you insert a cassette when listening to the radio, the tape will
start to play.
2-57
11. EXPLANATION OF COMPONENTS
REVERSING TAPE
When listening to the tape, press both FAST FORWARD, RE-
WIND buttons A and B at the same time lightly.
When this is done, the tape direction display will be reversed.
NOTICE
Handling cassette tape
‡ Clean the tape head approx. once a month with a commercially
available head. cleaning tape.
‡ Do not leave the tape in any place where it is exposed to direct
sunlight, any place that is excessively dusty, or any place where
there is a magnetic field.
‡ Do not use 120-minute tapes. The tape is thin and it is easily
gets caught up inside the machine.
‡ If the tape is slack, it easily gets caught up inside the machine.
Use a pencil to wind in the tape to remove any slack.
‡ Do not use any cassette tape if the label has started to come off.
It may cause defective rotation, or it may be impossible to get
the tape out of the machine.
2-58
11. EXPLANATION OF COMPONENTS
1. FAN SWITCH
This can be used to adjust the air flow to four stages.
This switch also acts as the main switch for the air conditioner.
When the OFF switch is pressed, the fan stops.
When the switch is pressed, the indicator lamp above the switch
lights up to indicate the air flow.
2-59
11. EXPLANATION OF COMPONENTS
2-60
11. EXPLANATION OF COMPONENTS
REMARK
If the temperature inside the operator’s compartment is low, the
air conditioner may not work. In such a case, warm the inside of the
operator’s compartment with recirculated air before turning the air
conditioner on.
2-61
11. EXPLANATION OF COMPONENTS
2-62
12. OPERATION
Before starting the engine, look around the machine and under
the machine to check for loose nuts or bolts, or leakage of oil, fuel,
or coolant, and check the condition of the work equipment and
hydraulic system.
Check also for loose wiring, play, and collection of dust at places
which reach high temperatures.
Always carry out the items in this section before starting the
engine each day.
2-63
12. OPERATION
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.
Check that there are no loose bolts on the equipment mounting
the seat belt to the machine, and tighten if necessary.
Tightening torque: 19.6 – 29.4 N·m (2.0 – 3.0 kgf·m, 14.5 – 21.7 lbft)
AE061620
2-64
12. OPERATION
Wear:
‡ Tires with a tread groove of less than 15% of that of a new
tire
‡ Tires with extreme uneven wear or with stepped-type wear
Damage:
‡ Tires with damage which has reached the cords, or with
cracks in the rubber
‡ Tires with cut or pulled cords
‡ Tires with peeled (separated) surface
‡ Tires with damaged bead
‡ Leaking or improperly repaired tubeless tires
‡ Deteriorated, deformed or abnormally damaged tires which
do not seem usable
2-65
12. OPERATION
2. Check that the monitors, gauges, and warning lamps light up for
approx. 3 seconds and the alarm buzzer sounds for approx. 1
second.
If any lamp does not light up, there may be a failure or discon-
nection in the monitor, so ask your Komatsu distributor to
inspect that monitor lamp.
3. When the CGC monitor starts up, check that the initial screen
appears for 2 – 3 seconds and then changes automatically to the
monitor screen.
(Initial screen)
(Monitor screen)
2-66
12. OPERATION
CAUTION
When adding water, use the handrail to support yourself se-
curely.
1. Open the cover at the rear left of the machine and check that the
coolant is within the range between the FULL and LOW marks
on the gauge shown in the diagram on the right. If the coolant
level is below the LOW mark, remove radiator cap 1 at the rear
of the machine and add water.
2-67
12. OPERATION
1. Open the inspection window at the rear left side of the machine.
2. Pull dipstick G out, then wipe the oil off with a cloth.
3. Insert dipstick G fully in the oil filler pipe (until there is a click),
then repeat Step 2 and take it out again.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
5. If the oil is above the H mark, loosen the plug of drain plug P,
and drain the excess engine oil. Do not simply drain the oil out;
use a vinyl tube and drain it into a container.
Then check the oil level again with the dipstick.
6. If the oil level is correct, tighten oil filler cap F securely, then
close the inspection window.
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, make it horizontal before checking.
2-68
12. OPERATION
NOTICE
‡ Check the oil level with the brake accumulator discharged.
‡ If the oil level is low, add oil to the tank on the side where the
level is low, and check for oil leakage from the brake piping line
for that tank.
1. Check the brake oil level in the brake oil tank on the left side of
the machine (near the rear frame center pin) with brake cooling
gauge 1 installed to the side of the brake tank and brake oil
gauge 2.
There are two brake tanks: tank A on the outside of the machine
is for the brake cooling, and tank B on the inside of the machine
is for the brake.
REMARK
“Accumulator discharged” means that there is no oil pressure in
the accumulator. To discharge the accumulator, stop the engine, and
depress the brake pedal several times until the oil pressure is
released.
2. If the oil level is low, open the cover at the top left of the
platform, then open tank cap 3 on the side which is low and add
engine oil.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
2-69
12. OPERATION
2. After completion of work, remove the mud guard cover and add
fuel through filler F until the fuel tank is full.
For details of the method for opening and closing the cap, see
“11.4 CAP WITH LOCK”.
Oil filler F is on both sides at the rear of the machine.
Add oil through one of the oil fillers at the side of the machine.
Oil is supplied to both tanks from each of the oil fillers.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
2-70
12. OPERATION
Check for damage and wrong capacity of the fuse and any sign of disconnection or short circuits in
the electric wiring. Check also for loose terminals and tighten any that are loose.
In particular, check the wiring of the battery, starting motor, and alternator carefully.
If there are any cracks in the starting motor cable terminals, replace the starting motor cable.
When carrying out checks around the battery, always check if there is any accumulation of flammable
material around the battery, and remove such flammable material.
Please contact your Komatsu distributor for investigation and correction of the cause.
CHECK PARKING BRAKE
Check that the parking brake works properly. If there is any abnormality in the operation of the
parking brake or the parking brake does not provide the proper braking effect, please contact your
Komatsu distributor for adjustment.
CHECK BRAKE
Drive the machine forward and test the effect of the brakes. If there is any abnormality in the
operation of the brake or the brake does not provide the proper braking effect, please contact your
Komatsu distributor for adjustment.
CHECK INFLATION PRESSURE OF TIRES
Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.
Check for damage or wear to the tires and the rims.
Check for loose wheel hub nuts (bolts).
The proper inflation pressure is shown below.
Size Inflation pressure
55.5/80-57-68PR(L5) (Standard) 0.59 MPa (6.0 kgf/cm2, 85.2 PSI)
65/65-57-62PR(L5) (If equipped) 0.49 MPa (5.0 kgf/cm2, 71.0 PSI)
NOTICE
The appropriate tire inflation pressure differs according to the type of work, so see “12.15
HANDLING TIRES”.
2-71
12. OPERATION
12.1.3 ADJUSTMENT
2-72
12. OPERATION
NOTICE
If the seat back is reclined too far, the seat back may hit the rear
glass, so use it in a position where it does not contact the glass.
H Lumbar support
Turn grip 5 to adjust the tension applied to the lower back.
2-73
12. OPERATION
1. Sit on the seat, depress the brake pedal fully, and adjust the seat
so that your back is pressed against the backrest.
2. After adjusting the seat position, adjust tether belt 1. Tense the
tether belt and install it when there is no one sitting on the seat.
3. Sit on the seat, pull the right side of the belt, then insert buckle
tongue 3 into buckle 2 until there is a click.
4. When removing the belt, press the red button in buckle 2 to free
the belt.
Fit the belt so that it follows your body and is not twisted.
1. Remove 2 bolts 1.
2. Loosen top and bottom bolts 2 without removing them.
3. Turn the mirror until it is close to the step handrail, then adjust
the angle of the mirror at this position.
Adjust the mirror angle so that the whole of the rear tire can be
seen from the operator’s seat.
2-74
12. OPERATION
REMARK
‡ If the directional switch is not at the N position, the alarm buzzer
will sound with short beeps.
‡ If the joystick steering lever is not at the neutral position, the
alarm buzzer will sound with a long beep.
If this is happens, return the joystick steering lever to the neutral
position (to the position where the alarm buzzer stops).
3. Lower the bucket to the ground, then check that work equipment
control lever 4 is locked by safety lock lever 5.
2-75
12. OPERATION
NOTICE
Do not keep the starting motor rotating 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.
REMARK
Even when the starting switch is returned to the ON position, the
starting condition is saved, so the operation from lubrication to
rotation of the starting motor is carried out automatically.
2-76
12. OPERATION
NOTICE
‡ Do not keep the starting motor rotating 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.
‡ Do not continue to spray the ether for more than 5 seconds.
‡ After the engine starts, do not spray ether under any circum-
stances.
If the ambient temperature goes below –10°C and the engine will
not start in the normal way, do as follows.
2-77
12. OPERATION
2-78
12. OPERATION
NOTICE
Avoid abrupt acceleration until the warming-up operation is
completed.
Do not run the engine at low idling or high idling for more than
20 minutes.
If it is necessary to run the engine at low idling or high idling,
apply a load or run at a mid-range speed from time to time.
2-79
12. OPERATION
1. Run the engine for 5 minutes at low idling to allow the engine
to cool down gradually.
2. Turn the key in starting switch 1 to the OFF position to stop the
engine.
2-80
12. OPERATION
2. Place safety lock lever 4 (of bucket control lever 2 and lift arm
control lever 3) and safety lock lever 6 (of joystick steering
lever 5) at the FREE position.
REMARK
If the safety lock lever for the joystick steering lever is not at the
FREE position, the directional switch will stay at the N position even
if it is operated. The FORWARD speed range display on the main
monitor will also stay at N and will not shift. Always be sure to set
the safety lock lever to the FREE position.
3. Operate lift arm control lever 3 to set the machine to the travel
posture shown in the diagram on the right.
A = 115 cm (4.5 in)
2-81
12. OPERATION
REMARK
If the parking brake remains applied even when parking brake
switch 7 is set to the OFF position, turn the parking brake switch ON,
then turn it OFF again.
REMARK
When starting the machine on a slope, set transmission cut-off
switch D to the OFF position, depress left brake pedal E, set to the
desired gear speed, then depress accelerator pedal C and gradually
release left brake pedal E to let the machine move off. This will
prevent the machine from moving in reverse.
2-82
12. OPERATION
REMARK
This machine is equipped with kick-down switch 4. This shifts
the gear down to 1st if the button at the tip of the lift arm control
lever is pressed when the machine is traveling in 2nd gear.
We recommend the use of the kick-down switch when carrying out
digging or loading operations in 1st or 2nd gear.
For details of the method of use, see “11.2 SWITCHES, KICK-DOWN
SWITCH”.
2-83
12. OPERATION
If you shift down the gear at high travel speed, the warning buzzer sounds for 3 seconds (quick
intermittent sound) and the controller controls the gear shifting down operation to maintain the durability
of the torque converter according to the following table.
Be careful that the deceleration of the machine is lowered in this case.
Operation of
gear shift Engine Command from controller
lever speed
2100
3rd 3rd
1200
2100
3rd➞2nd 3rd
1200
2nd &Caution
2100
2100
2nd➞1st 1st 2nd
1200 &Caution
2100
Kick-down
from F2nd 1200
Shifted to 1st Kept at 2nd
0 5 7 10 12 15 17 Above 20
Travel speed (km/h)
2-84
12. OPERATION
‡ Shift-down limit
Operation of shift-
down Command from controller
switch
14
2nd & 3rd &
3rd ➞ 2nd 2nd Caution Caution
2nd &
2nd ➞ 1st 1st
Caution
2-85
12. OPERATION
‡ Shift-down limit
Manual shift
Operation of shift-
down Command from controller
switch
14
2nd & 3rd &
3rd ➞ 2nd 2nd Caution Caution
2nd &
2nd ➞ 1st 1st
Caution
2-86
12. OPERATION
I II
3rd 2nd 3rd &
Caution
I II
2nd 2nd 3rd &
Caution
When
gear I II
3rd & Recovery from
speed is 1st 2nd kick-down
Caution
2nd or 3rd
When
gear I II II Switching F R
1st 2nd & 3rd &
speed is 1st when held in 1st
Caution Caution
1st
Operation of shift-
down Command from controller
switch
II
3rd ➞ 2nd I 3rd &
2nd Caution
When kick-down switch is
II II
3rd & received twice while
3rd ➞ 1st I 1st 2nd &
Caution Caution traveling at a speed of
more than 14 km/h
II
2nd ➞ 1st I 1st 2nd &
Caution
2-87
12. OPERATION
I II
3rd 3rd &
2nd Caution
I II
2nd 3rd &
2nd
Caution
When speed I II II
1st 2nd & 3rd & Switching F R
range judge- 1st
ment is 1st Caution Caution when held in 1st
Operation of shift-
down Command from controller
switch
6
II
3rd ➞ 2nd I 3rd &
2nd Caution
When kick-down switch is
II II
3rd & received twice while
3rd ➞ 1st I 1st 2nd &
Caution Caution traveling at a speed of
more than 14 km/h
II
2nd ➞ 1st I 1st 2nd &
Caution
2-88
12. OPERATION
NOTICE
When traveling, never use the parking brake switch to brake the
machine except in an emergency. Apply the parking brake only after
the machine has stopped.
REMARK
When the parking brake is applied, the transmission is automati-
cally returned to neutral.
2-89
12. OPERATION
REMARK
When turning fully, do not operate the steering lever beyond the
end of the stroke.
Check also that the operation of the steering is normal. If any
abnormality is found, please contact your Komatsu distributor for
inspection.
2-90
12. OPERATION
When the lift arm control lever is pulled further from the raise
position, the lever is stopped in this position until the lift arm reaches
the preset kick-out position, the lever is returned to the HOLD
position.
NOTICE
Do not use the FLOAT position when lowering the bucket.
Use the FLOAT position for leveling work, see “12.9.2 LEVELING
OPERATIONS”.
When the bucket control lever is pulled further from the tilt
position, the lever is stopped in this position until the bucket reaches
the preset position of the bucket positioner, then the lever is re-
turned to the hold position.
2-91
12. OPERATION
NOTICE
If the tires slip, the tire life will be reduced, so do not allow the
tires to slip during operation.
1. When driving the machine forward and lowering the bucket, stop
the bucket about 30 cm (12 in) from the ground, then lower it
slowly.
REMARK
If the bucket hits the ground, the front tires will come off the
ground, and the tires will slip.
2-92
12. OPERATION
4. At the same time as thrusting the bucket into the material, raise
the lift arm to prevent the bucket from going in too far. By raising
the lift arm, ample traction will be produced by the front tires.
REMARK
If the bucket is thrust in too much and the lift arm stops rising
or the machine stops moving forward, release the accelerator pedal
a little.
Proper operation of the accelerator pedal for each type of the
soil is effective for saving fuel and prevention of wear of the tires.
5. Check that there is enough material loaded into the bucket, then
operate the bucket control lever to tilt the bucket and load the
bucket fully.
REMARK
If the bucket edge is moved up and down while pushing in the
bucket and digging, the front tires will come off the ground and this
will cause the tires to slip.
6. If there is too much material loaded in the bucket, dump and tilt
the bucket quickly to remove the excessive load. This prevents
spillage of the load during hauling.
2-93
12. OPERATION
2. Drive the machine forward and operate the lift arm control lever
forward to cut a thin layer of the surface each time when
excavating the soil.
3. Operate the lift arm control lever slightly up and down to reduce
the resistance when driving the machine forward.
When digging with the bucket, avoid applying the digging force
onto only one side of the bucket.
2-94
12. OPERATION
NOTICE
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 dumping angle to more than 20°.
1. Scoop 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 edge of the bucket touching the
ground and level the ground by back-dragging.
3. Scoop some more soil into the bucket, set the bucket horizontal,
put the lift arm at FLOAT, and move in reverse to smooth the
ground.
AE061970
The load and carry method for wheel loaders consists of a cycle
of scooping ➞ hauling ➞ loading (into a hopper, glory hole, etc.)
Always keep the travel path properly maintained.
When using the load and carry method, see “12.15.3 PRECAU-
TIONS WITH LOAD AND CARRY METHOD”.
2-95
12. OPERATION
NOTICE
‡ If the tires slip, the tire life will be reduced, so do not allow the
tires to slip during operation.
‡ Avoid excessive shaking of the bucket.
2-96
12. OPERATION
V-SHAPE LOADING
Position the dump truck so that the direction of approach of the
wheel loader is approx. 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 is, 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.
REMARK
As far as possible, do not use the transmission cut-off function
during scraping-up operation. This will prevent the machine from
rolling back.
NOTICE
Do not carry out operations scraping up floating rocks.
An unexpectedly excessive load will be brought to bear and this
may cause damage to the machine.
2-97
12. OPERATION
NOTICE
‡ If the parking brake has been used as an emergency brake,
contact your Komatsu distributor to have the parking brake
checked for any abnormality.
IF ENGINE STOPS
If the engine stops on a slope, apply the parking brake immedi-
ately, and lower the work equipment to the ground and stop the
machine. Then put the directional switch at the N position, and start
the engine again.
2-98
12. OPERATION
Ambient Continuous
temperature (°C) Tire Tire conditions travel distance
(Standard)
55.5/80-57-68PR (L5)
(Standard tire inflation pressure At least 24 hours
0.59 MPa (6.0 kgf/cm2, 85.2 PSI) after completion
Max. 25 km
Max. 45 of work, when tire
(Max. 15.5 MPH)
(If equipped) temperature has
65/65-57-62PR (L5) gone down
(Standard tire inflation pressure)
0.49 MPa (5.0 kgf/cm2, 71.0 PSI)
2-99
12. OPERATION
2-100
12. OPERATION
NOTICE
Never use the parking brake switch to brake the machine when
traveling except in an emergency. Apply the parking brake only
after the machine has stopped.
NOTICE
When the parking brake is applied, the transmission is auto-
matically returned to neutral.
2-101
12. OPERATION
5. Lock lift arm control lever 5 and bucket control lever 6 with
safety lock lever 7.
6. Set joystick steering lever 8 to the neutral position, then lock the
steering lever with safety lock lever 9.
2-102
12. OPERATION
12.14 LOCKING
Always lock the following places.
REMARK
The starting switch key is used for locking places 1, 2, 3, 4,
5, and 6.
2-103
12. OPERATION
2-104
12. OPERATION
Clearing fallen stones and rocks from the operating area and
maintaining the surface will extend the tire life and give improved
economy.
‡ For operations on normal road surfaces, rock digging opera-
tions: High end of range in chart below
‡ Stockpile operations on soft ground: Average pressure in chart
below
H Inflation pressure
Tire size Free height Normal road When shipped
(pattern) (mm) Stockpile Digging from factory
0.54 – 0.59 0.54 – 0.59 Both front
55.5/80-57-68PR MPa MPa and rear
(L5 Rock) 929 (5.5 – 6.0 (5.5 – 6.0 0.59 MPa
(Standard) kgf/cm2, kgf/cm2, (6.0 kgf/cm2,
78.1 – 85.2 PSI) 78.1 – 85.2 PSI) 85.2 PSI)
0.44 – 0.49 0.44 – 0.49 Both front
65/65-57-62PR MPa MPa and rear
(L5 Rock) 992 (4.5 – 5.0 (4.5 – 5.0 0.49 MPa
(If equipped) kgf/cm2, kgf/cm2, (5.0 kgf/cm2,
63.9 – 71.0 PSI) 63.9 – 71.0 PSI) 71 PSI)
2-105
12. OPERATION
(1) Initial screen: This screen is displayed for approx. 15 seconds after the monitor operation starts.
(2) Monitor screen: This screen shows the engine water temperature gauge, torque converter oil
temperature gauge, fuel gauge, engine tachometer, time display, and selector
switches for each screen. For details, see “MONITOR SCREEN”.
(3) Maintenance screen:
This displays the maintenance items and the time remaining until the next
maintenance. For details, see “MAINTENANCE SCREEN”.
(4) Setting screen: This displays the present time, the units for the data displayed on the monitor, and
the user ID, and also switches the language. For details, see “SETTING SCREEN”.
(5) Fuel consumption screen:
This displays the productivity in ton/hour, the fuel consumption in liter/hour, and
the data measurement interval. For details, see “FUEL CONSUMPTION SCREEN”.
2-106
12. OPERATION
2-107
12. OPERATION
INITIAL SCREEN
This screen is displayed when the engine starting switch is
turned ON. After approx. 15 seconds, it automatically switches to the
monitor screen.
During this 15 seconds, it checks if the VHMS controller is
working properly. If everything is normal, it switches to the monitor
screen.
MONITOR SCREEN
This screen shows engine water temperature gauge 1, torque
converter oil temperature gauge 2, fuel gauge 3, engine tachom-
eter 9, and time 0.
In addition, there are also switches to change to loadmeter
screen 8, positioner screen A, fuel consumption screen 6, setting
screen 5, maintenance screen 4, and brightness adjustment screen
7, and failuer list screen B.
MAINTENANCE SCREEN
This is used to check the maintenance items and the time
remaining of the maintenance interval set for each item. The opera-
tion when the maintenance time has been reached can also be
carried out.
2-108
12. OPERATION
2-109
12. OPERATION
2-110
12. OPERATION
SETTING SCREEN
The operations for inputting the date and time, setting the units
used, registering the user ID number, and switching the language
used can be carried out.
2-111
12. OPERATION
‡ Setting unit
1. Press [UNIT] switch 3 displayed on the screen. Three switches
(METRIC, ENGLISH, SI) are displayed on the screen.
REMARK
On the Warning/failure display screen when the display has been
canceled with the [cancel] switch, if the user ID number is changed,
the presently existing failures are displayed again.
This function makes it possible to check the condition of the
machine whenever the operators change shifts.
2-112
12. OPERATION
2-113
12. OPERATION
‡ Productivity display
1. Press the [fuel consumption screen] selector switch at the
bottom left of the monitor screen.
2-114
12. OPERATION
REMARK
Once the data have been cleared, they cannot be restored. Check
carefully before pressing the [YES] switch to clear the data.
3. After checking that the data have been deleted, press the
[return] switch at the bottom left of the screen to return to
the “Consumption” screen.
2-115
12. OPERATION
POSITIONER SCREEN
This is the system to set the stopping position when raising or
lowering the lift arm and to slow the lift arm down and stop it when
it approaches the set position.
2. Operate the lift arm control lever to raise the lift arm.
Determine the stopping position of the lift arm, then return
the control lever to the neutral position and stop the move-
ment of the lift arm. (Set the UPPER position at a point where
the lift arm is above horizontal.)
2-116
12. OPERATION
2. Operate the lift arm control lever to lower the lift arm.
Determine the stopping position of the lift arm, then return
the control lever to the neutral position and stop the move-
ment of the lift arm. (Set the LOWER position at a point
where the lift arm is below horizontal.)
2. Operate the lift arm control lever in the same way as in Steps
2 to 5 when setting the UPPER and LOWER stop positions.
2-117
12. OPERATION
LOADMETER SCREEN
The loadmeter has two types of screen: the addition mode
screen and the subtraction mode screen. Select the appropriate
screen according to the need.
2-118
12. OPERATION
REMARK
Once the data have been cleared, they cannot be restored. Check
carefully before pressing the [YES] switch to clear the data.
‡ Calibration display
CAUTION
When carrying out the calibration, warm up the engine and
carry out calibration under the same conditions as for actual
work.
‡ Other displays
1. If the engine water temperature, torque converter oil tem-
perature, and fuel gauge display switch 8 at the bottom of
the “LOADMETER ADDITION MODE” is pressed, the engine
water temperature, torque converter oil temperature, and
fuel gauge will be displayed at the right side of the screen.
To delete the display, press switch 8 again, and the screen
will return to the previous screen.
2-119
12. OPERATION
‡ Other displays
On the loadmeter subtraction mode screen, there are the following selector switches. These switches
are the same as the items already explained for the loadmeter addition mode screen.
KIND selector switch 2
Calibration selection switch 6
Total payload display switch 7
Engine water temperature, torque converter oil temperature, fuel gauge display switch 9
Monitor screen return switch 0
2-120
12. OPERATION
[Operation procedure]
To make the screen easy to see, adjust the brightness and
contrast as follows.
1) Set the [Contrast] switch to “50”.
2) Next, set the [Brightness] switch to the desired position.
3) Finally, set the [Contrast] switch to the desired setting.
REMARK
‡ The brightness can be adjusted to two levels (day level and night
level), and the brightness and contrast settings for each condi-
tion can be saved. The system distinguishes between day and
night according to the ON-OFF position of the light switch.
‡ To change the settings, operate the [Brightness] switch or [Con-
trast] according to the conditions.
2-121
12. OPERATION
2-122
12. OPERATION
NOTICE
Do not remove follower plate 2. If follower plate 2 is not used,
pump 3 will be unable to suck up grease even if there is still a large
quantity of grease in the can.
In the following cases, the lamp will flash at 0.5 second intervals.
1) Empty cartridge, broken circuit
The circuit pressure when the pump is actuated does not rise
to the set pressure and cannot carry out greasing
2) Power supply cut
The power supply is cut and the system cannot function
3) Defective release of pressure
After completion of greasing, the circuit pressure does not
go down and the plunger does not return, so the next
greasing cannot be carried out
4) Even when normal, during period until pressure inside the
circuit rises to set pressure
If the lamp still flashes after the grease pump is filled with
grease, consult your Komatsu distributor.
2-123
12. OPERATION
2. Auto-greasing switch 1
If auto-greasing switch 1 is pressed, the grease pump can be
operated, regardless of the timer. The grease pump operates
only while the auto-greasing switch is kept pressed. The grease
pump stops immediately when the auto-greasing switch is re-
leased.
This switch is used mainly to check the operation of the grease
pump or to supply additional grease.
2-124
12. OPERATION
NOTICE
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.
2-125
12. OPERATION
2-126
12. OPERATION
1 Center hinge pin (upper) 5 Transmission support 8 Rear axle support (front)
2 Steering cylinder (bottom right) R2 6 Rear axle support (top) 9 Center hinge pin (lower)
F
3 Steering cylinder (bottom left) 7 Rear axle support (center) R1 0 Fuel oil cooler
4 Center support A Steering cylinder (rod left)
B Steering cylinder (rod right)
2-127
13. TRANSPORTATION
2-128
14. COLD WEATHER OPERATION
14.1.2 COOLANT
WARNING
‡ Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into
your eyes or on your skin, wash it off with large quantities of fresh water and see a doctor at
once.
‡ Antifreeze is toxic. Be extremely careful when handling it. When replacing coolant containing
antifreeze or when handling coolant when repairing the radiator, ask your antifreeze dealer or
contact your Komatsu distributor. Be careful not to let the water flow into drainage ditches or
spray on to the ground surface.
‡ Antifreeze is flammable, so do not bring any flame close. Do not smoke when handling antifreeze.
NOTICE
‡ Never use methanol, ethanol or propanol based antifreeze.
‡ Absolutely avoid using any water leak preventing agent irrespective of whether it is used independ-
ently or mixed with an antifreeze.
‡ Do not mix one antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant, see “24.2 WHEN REQUIRED”.
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 ...................................................................................................................................................... J1034
‡ 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. 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.
2-129
14. COLD WEATHER OPERATION
14.1.4 BATTERY
WARNING
‡ The battery generates flammable gas, so 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 see a doctor at once.
‡ Battery electrolyte dissolves paint. If it gets on to the bodywork, wash it off immediately with
water.
‡ If the battery electrolyte is frozen, do not charge the battery or start the engine with a different
power source. There is danger that this will cause an explosion.
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 that the machine can be started easily the next morning.
REMARK
Measure the specific gravity and calculate the rate of charge from the following conversion table.
Temp.
of fluid
20°C 0°C –10°C –20°C
Rate of
charge
‡ As the battery capacity drops markedly in low temperatures, cover the battery or remove it from the
machine, keep it in a warm place to maintain the temperature, and install it again the next morning.
‡ If the battery electrolyte level is low, do not add distilled water after finishing work for the day. This
is to prevent the electrolyte from freezing during the night. Wait until the next morning and add
distilled water before starting work.
2-130
14. COLD WEATHER OPERATION
When the temperature is low, do not start the operation of the machine immediately after starting
the engine.
NOTICE
Operate the steering lever a little and stop in that position. Then, confirm that the machine is being
steered by an angle equivalent to the amount that the steering lever is operated.
Recommended oil
Select the oil depending on the temperature as shown in the following table.
AMBIENT TEMPERATURE
KIND OF
RESERVOIR
FLUID –22 –4 14 32 50 68 86 104122˚F
–30 –20 –10 0 10 20 30 40 50˚C
SAE10WCD
Hydraulic system Engine oil
SAE5W–20CD
If SAE5W-20CD is used in the cold season, replace it with SAE10WCD after the cold season.
2-131
15. LONG-TERM STORAGE
‡ Operate the engine and move the machine for a short distance once a month so that a new film of
oil will be coated over the lubricated parts. At the same time, also charge the battery.
‡ Before operating the work equipment, wipe off the grease from the hydraulic piston rods.
‡ If the machine is equipped with an air conditioner, operate it for 3 – 5 minutes once a month to
lubricate each portion of its compressor. Be sure to idle the engine at low speed and operate the
cooler. Also, check the quantity of refrigerant twice a year.
Carry out the following procedure when taking the machine out of long-term storage.
‡ Wipe off the grease from the hydraulic cylinder piston rods.
‡ Add oil and grease to all places.
‡ In the case of long-term storage, the moisture in the air will enter the oil. Check the oil at all parts
before and after starting the engine. If there is any water in the oil, replace all the oil.
2-132
16. TROUBLESHOOTING
If the machine has run out of fuel, add fuel and then do as
follows.
5. Remove plug 4 from the top of the engine fuel injection pump,
then fill the fuel injection pump with fuel. (Amount of fuel: 5 ¬
(1.32 US gal))
After filling with fuel, tighten plug 4.
2-133
16. TROUBLESHOOTING
NOTICE
‡ Towing is for moving the machine to a place where inspection and maintenance can be carried out,
and not for moving it long distances.
Do not tow the machine for long distances.
‡ For details of the procedure for towing a machine when it has broken down, please contact your
Komatsu distributor.
This machine must not be towed except in emergencies. When towing the machine, take the
following precautions.
‡ Put blocks under the wheels to prevent the machine from moving when the brakes are released. If
the wheels are not blocked the machine may move.
‡ When towing a machine, tow it at a low speed of less than 2 km/h (1.2 MPH), and for a distance
of a few meters to a place where repairs can be carried out.
The machine should be towed only in emergencies. If the machine must be moved long distances,
use a transporter.
‡ Fit a guard plate to the machine being towed to protect the operator if the tow rope or bar should
break.
‡ If the steering and brakes of the machine being towed cannot be operated, do not let anyone sit on
the machine.
‡ Check that 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 a
strength of at least 1.5 times the weight of the machine being towed.
‡ Keep the angle 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 moved suddenly, an excessive load will be applied to the tow rope or bar and it
may break. Always move the machine slowly at a constant speed.
‡ The towing machine should normally be of the same class as the machine being towed. Check that
the towing machine has ample braking power, weight, and rimpull to allow it to control both
machines on slopes or on the tow road.
‡ When towing a machine downhill, to provide ample rimpull and braking power, use a larger machine
for towing 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 various differing conditions, so it is impossible to determine
beforehand the requirements for towing. Towing on flat horizontal roads will require the minimum
rimpull, while towing on slopes or on uneven road surfaces will require the maximum rimpull.
2-134
16. TROUBLESHOOTING
1. The transmission oil does not lubricate the system, so remove the front and rear drive shafts. If
necessary, block the tires to prevent the machine from moving.
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.
4. Parking brake
The parking brake cannot be turned OFF. To release the parking brake, do as follows.
NOTICE
When carrying out the release operation after the parking brake has failed, please contact your
Komatsu distributor to have the parking brake released.
NOTICE
Always request your Komatsu distributor to carry out the emergency travel operation.
2-135
16. TROUBLESHOOTING
REMARK
There are 3 batteries each (total: 6) on both sides at the rear of
the machine.
2-136
16. TROUBLESHOOTING
‡ Set the charging current to 1/10 of the value of the rated battery
capacity; when carrying out rapid charging, set it to less than the
rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry
up, and this may cause the battery to catch fire and explode.
2-137
16. TROUBLESHOOTING
NOTICE
‡ The thickness of the booster cable and clip should be suitable
for the battery size.
‡ The battery of the normal machine must be the same capacity
as that of the problem machine.
‡ Check the cables and clips for damage or corrosion.
‡ Make sure that the cables are firmly connected.
‡ Check that the safety lock levers and the parking brakes of both
machines are at the LOCK position.
‡ Check that all the levers are at the neutral position.
2-138
16. TROUBLESHOOTING
1. Make sure the clips are firmly connected to the battery terminals.
2. Turn the starting switch of the problem machine to the START
position and start the engine. If the engine doesn’t start at first,
wait for at least 2 minutes before trying again.
2-139
16. TROUBLESHOOTING
Lamp does not glow brightly even ‡ Defective wiring (‡ Check, repair loose terminals,
when the engine runs at high disconnections)
speed
Lamp flickers while engine is ‡ Defective fan belt tension ‡ Adjust alternator belt tension,
running see EVERY 250 HOURS
SERVICE
Prelube motor does not work and ‡ Defective wiring (‡ Check, repair)
starting motor does not turn when ‡ Insufficient battery charge ‡ Charge
starting switch is turned to ON
2-140
16. TROUBLESHOOTING
16.4.2 CHASSIS
‡ ( ): Always contact your Komatsu distributor when dealing with these items.
‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu
distributor for repairs.
Transmission
Engine is running but machine does ‡ Parking brake is applied ‡ Release parking brake
not move ‡ Directional switch is not operated ‡ Operate switch properly
properly
‡ Lack of oil in transmission case ‡ Add oil to specified level,
see WHEN REQUIRED
Even when engine is run at full ‡ Lack of oil in transmission case ‡ Add oil to specified level,
throttle, machine only moves slowly see WHEN REQUIRED
and lacks power ‡ Transmission strainer is clogged ( ‡ Disassemble, clean)
Oil overheats ‡ Too much oil or too little oil ‡ Add or drain oil to specified
level, see WHEN REQUIRED
‡ Machine is not traveling in ‡ Place in correct speed range
correct speed range
‡ Torque converter is stalled for ‡ Reduce stall time
long periods
‡ Engine is overheating ( ‡ Check engine)
Axle
Disc brake
Brake has no effect even when ‡ Disc has reached wear limit ( ‡ Replace disc)
pedal is depressed ‡ Defective hydraulic system
‡ Lack of oil ‡ Add oil to specified level,
see CHECKS BEFORE STARTING
‡ Air in brake line ‡ Bleed air.
See WHEN REQUIRED
2-141
16. TROUBLESHOOTING
Parking brake
Steering
Steering lever is heavy ‡ Defective hydraulic system ‡ See EVERY 100 HOURS
SERVICE
Hydraulic system
Bucket lacks lifting power ‡ Lack of oil ‡ Add oil to specified level,
see EVERY 100 HOURS
SERVICE
Bucket takes time to rise ‡ Clogged hydraulic tank filter ‡ Replace filter, see EVERY 2000
HOURS SERVICE
Excessive bubbles in oil ‡ Low quality oil being used ‡ Replace with good quality oil
‡ Oil level is low ‡ Add oil to specified level,
see EVERY 100 HOURS SERVICE
‡ Air in oil line ‡ Bleed air, see WHEN REQUIRED
Hydraulic pressure is low ‡ Oil level is low and pump is ‡ Add oil to specified level,
sucking in air see EVERY 100 HOURS
SERVICE. Then bleed air,
see WHEN REQUIRED
Movement of cylinder is irregular ‡ Oil level is low ‡ Add oil to specified level,
see EVERY 100 HOURS SERVICE
‡ Leakage inside cylinder (‡ Replace, repair)
2-142
16. TROUBLESHOOTING
16.4.3 ENGINE
‡ ( ): Always contact your Komatsu distributor when dealing with these items.
‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu
distributor for repairs.
Engine oil pressure caution appears ‡ Engine oil pan level is low ‡ Add oil to specified level,
on CGC monitor (sucking in air) see CHECK BEFORE STARTING
‡ Clogged oil filter cartridge ‡ Replace cartridge, see EVERY
250 HOURS SERVICE
‡ Defective tightening of oil pipe, (‡ Check, repair)
pipe joint, oil leakage from
damaged part
‡ Defective pilot lamp (‡ Replace)
Steam is emitted from top part of ‡ Cooling water level low ‡ Add cooling water, repair,
radiator (pressure valve) see CHECK BEFORE STARTING
‡ Loose fan belt ‡ Adjust fan belt tension,
see EVERY 250 HOURS SERVICE
Engine water temperature caution ‡ Dirt or scale accumulated in ‡ Change cooling water, clean
appears on CGC monitor cooling system inside of cooling system,
see WHEN REQUIRED
‡ Clogged radiator fin or damaged ‡ Clean or repair, see WHEN
fin REQUIRED
‡ Defective thermostat (‡ Replace thermostat)
‡ Loose radiator filler cap ‡ Tighten cap or replace packing
(high altitude operation)
‡ Defective pilot lamp (‡ Replace)
Engine does not start when starting ‡ Lack of fuel ‡ Add fuel, see CHECK BEFORE
motor is turned STARTING
‡ Air in fuel system ‡ Repair place where air is sucked
in
‡ Defective fuel injection pump or (‡ Replace pump or nozzle)
nozzle
‡ Starting motor cranks engine ‡ See ELECTRICAL SYSTEM
sluggishly
‡ Defective compression
‡ Defective valve clearance (‡ Adjust valve clearance)
Exhaust gas is white or blue ‡ Too much oil in oil pan ‡ Add oil to specified level,
see CHECK BEFORE STARTING
‡ Improper fuel ‡ Change to specified fuel
2-143
16. TROUBLESHOOTING
Exhaust gas occasionally turns black ‡ Clogged air cleaner element ‡ Clean or replace, see WHEN
REQUIRED
‡ Defective nozzle (‡ Replace nozzle)
‡ Defective compression (‡ See defective compression
above)
‡ Defective turbocharger (‡ Clean or replace turbocharger)
Abnormal noise generated ‡ Low grade fuel being used ‡ Change to specified fuel
(combustion or mechanical) ‡ Overheating ‡ See “Engine water tempera
ture pilot lamp lights up”
above
‡ Damage inside muffler (‡ Replace muffler)
‡ Excessive valve clearance (‡ Adjust valve clearance)
2-144
MAINTENANCE
WARNING
Before reading the MAINTENANCE section, be sure that you
have read and understood the SAFETY section.
3-1
17. GUIDES TO MAINTENANCE
Do not carry out any inspection and maintenance operation that is not given in this manual.
Fuel strainer:
If your machine is equipped with a fuel strainer in the fuel filler, do not remove it while fueling.
Welding instructions:
‡ Turn off the power. (Turn off the engine starting switch.)
‡ Do not apply more than 200V continuously.
‡ Connect the grounding cable within 1 m (3 ft 3 in) from the area to be welded. Do not connect the
grounding cable near any gauges or connectors. This will cause failure of the gauges.
‡ Avoid seals or bearings from being between the area to be welded and the grounding point. Sparks
generated when welding will cause damage to the seals.
‡ Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding
point. Sparks generated when welding will cause damage to the plated parts.
Dusty worksites:
When working at dusty worksites, do as follows.
‡ Check the air cleaner clogging monitor more frequently to check the condition of clogging.
Clean the air cleaner element at shorter intervals than specified.
‡ Clean the radiator core at shorter intervals than specified to prevent it from clogging.
‡ Clean and replace the fuel filter more frequently.
‡ Clean electrical components, especially the starting motor and alternator, to avoid accumulation of
dust.
‡ When checking or changing the oil, move the machine to a place where there is no dust to prevent
dirt or dust from entering.
3-2
17. GUIDES TO MAINTENANCE
3-3
18. OUTLINES OF SERVICE
18.1.2 FUEL
‡ The fuel pump is a precision instrument. It will stop working if there is oil or water mixed in the
fuel.
‡ Be extremely careful not to let impurities get in when storing or adding fuel.
‡ Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperatures
below –15°C (5°F)), so it is necessary to change to a fuel that matches the temperature.
‡ To prevent the moisture in the air from condensing and forming water inside the fuel tank, always
fill the fuel tank after completing the day’s work.
‡ Before starting the engine, or when 10 minutes have passed after adding fuel, 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.
18.1.3 COOLANT
‡ River water contains large amounts of calcium and other impurities, so if it is used, scale will stick
to the engine and radiator, and this will cause defective heat exchange and will result in overheating.
Do not use water that is not suitable for drinking.
‡ When using antifreeze, always observe the precautions given in the Operation and Maintenance
Manual.
‡ Komatsu machines are supplied with Komatsu specified antifreeze in the coolant when the machine
is shipped.
This antifreeze is effective in preventing corrosion of the cooling system and it can be used as it is
even in hot areas.
The antifreeze can be used continuously for two years or 4000 hours. Therefore, it can be used as
it is even in hot areas.
‡ Antifreeze is flammable, so be extremely careful not to expose it to flame or fire.
‡ The proportion of antifreeze to water differs according to the ambient temperature.
For details of the mixing proportions, see “24.2.2 CLEAN INSIDE OF COOLING SYSTEM”.
3-4
18. OUTLINES OF SERVICE
‡ Use cooling water mixed with the specified additive, and maintain it at a suitable density.
‡ If the engine overheats, wait for the engine to cool before adding coolant.
‡ If the coolant level is low, it will cause overheating and will also cause problems with corrosion by
air entering the coolant circuit.
18.1.4 GREASE
‡ Grease is used to prevent twisting and noise at the joints.
‡ The grease fittings not included in the MAINTENANCE section are grease fittings for overhaul, so
they do not need grease.
If any part becomes stiff or makes noise after being used for long time, apply grease.
‡ Always wipe off all the old grease that is pushed out when greasing. Be particularly careful to wipe
off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating
parts.
‡ Others
Measurements are made of items such as the ratio of water or
fuel in the oil, and the dynamic viscosity.
Oil sampling
‡ Sampling interval
250 hours: Engine
500 hours: Other components
3-5
18. OUTLINES OF SERVICE
18.1.7 FILTERS
‡ Filters are extremely important safety parts. They prevent impurities in the oil, fuel, and air circuits
from entering important equipment and causing problems. Replace all filters periodically. For details,
see the Operation and Maintenance Manual.
However, when working in severe conditions, it is necessary to consider replacing the filters at
shorter intervals according to the oil and fuel (sulphur 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, please contact your Komatsu distributor.
‡ Do not open packs of spare filters until just before they are to be used.
‡ Always use Komatsu genuine filters.
3-6
19. WEAR PARTS LIST
Wear parts such as the filter element, air cleaner element, bolt on edge, etc. are to be replaced at
the time of periodic maintenance or before their abrasion limits.
The wear parts should be changed correctly in order to use the machine economically.
For part change, Komatsu genuine parts of excellent quality should be used.
When ordering parts, please check the part number in the parts book.
07063-01210 Element 2
Transmission oil filter EVERY 500 HOURS
(07000-15180) O-ring (2)
208-60-61180 Element 3
Hydraulic filter (07000-12010) (O-ring) (3) EVERY 2000 HOURS
(07000-15210) (O-ring) (3)
3-7
20.USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING
TO AMBIENT TEMPERATURE
SAE 10W-30
Engine oil pan 300 ¬ 260 ¬
SAE 15W-40 79.20 US gal 68.64 US gal
SAE 5W-30
ªª Please use GL-5 class oil for the SAE80W-90 gear oil. Do not use GL-4 class oil.
ªªª For machines equipped with the auto-greasing system, if the machine is operated in temperatures
below –20°C, change the grease to lithium-based grease No. 0.
When operating the machine at temperatures below –20°C, other equipment is needed, so please
consult your Komatsu distributor.
Note 1:
For axle oil, use only recommended oil as follows.
SHELL: DONAX TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBILFLUID 424
3-8
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
REMARK
‡ When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
‡ When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine
oil of SAE10W-30, SAE15W-40, or SAE5W-30, even though the atmospheric temperature goes up to
about 10°C during the day.
Use CE or CF class oil for the engine oil.
‡ Use API classification CD as engine oil and if API classification CC, reduce the engine oil change
interval to half.
‡ There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be
sure to add single grade oil that matches the temperature in the table.
‡ We recommend Komatsu genuine oil which has been specifically formulated and approved for use
in engine and hydraulic work equipment applications.
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.
3-9
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
Engine Oil
Anti-freeze
[CD or CE]
Coolant
SAE10W, 30, 40 Gear Oil Grease
No. Supplier [Ethylene Glycol
10W30, 15W40 [GL-4 or GL-5] [Lithium-Base]
Base]
(The 15W40 oil SAE80, 90, 140 NLGI No. 2
Permanent Type
marked * is CE.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT (Winter, one
EO15-40CD season type)
Diesel sigma S
Super dieselmulti-
2 AGIP Rotra MP GR MU/EP –
grade
*Sigma turbo
Litholine HEP 2
4 ARCO *Arcofleet S3 plus Arco HD gear oil –
Arco EP moly D
Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C
Universal gear
9 CONOCO *Fleet motor oil Super-sta grease –
lubricant
Multiperformance 3C Tranself EP
10 ELF – Glacelf
Performance 3C Tranself EP type 2
Essolube D3
*Essolube XD-3
EXXON Gear oil GP
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifreeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant
3-10
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
Engine Oil
Anti-freeze
[CD or CE]
Coolant
SAE10W, 30, 40 Gear Oil Grease
No. Supplier [Ethylene Glycol
10W30, 15W40 [GL-4 or GL-5] [Lithium-Base]
Base]
(The 15W40 oil SAE80, 90, 140 NLGI No. 2
Permanent Type
marked * is CE.)
Multi-purpose white
*Supreme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White – bearing summer coolant
grease
FINA potonic N
15 PETROFINA FINA kappa TD FINA marson EPL2 FINA tamidor
FINA potonic NE
Spirax EP
16 SHELL Rimula X Alvania EP grease –
Spirax heavy duty
Total EP
Rubia S
19 TOTAL Total transmission Multis EP2 Antigel/antifreeze
*Rubia X
TM
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B – Antifreeze
MDC Multigear C
3-11
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND
NUTS
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
The tightening torque is determined by the width across the flats of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as
the part that was replaced.
Thread Width
Tightening torque
diameter across
a (mm) flat Target value Service limit
b (mm) N·m kgf·m lbft N·m kgf·m lbft
6 10 13.2 1.35 9.8 11.8 – 14.7 1.2 – 1.5 8.7 – 10.8
8 13 31 3.2 23.1 27 – 34 2.8 – 3.5 20.3 – 25.3
10 17 66 6.7 48.5 59 – 74 6.0 – 7.5 43.4 – 54.2
12 19 11 11.5 83.2 98 – 123 10.0 – 12.5 72.3 – 90.4
14 22 177 18 130.2 157 – 196 16.0 – 20.0 115.7 – 144.7 b
16 24 279 28.5 206.1 245 – 309 25.0 – 31.5 180.8 – 227.8
18 27 382 39 282.1 343 – 425 35.0 – 43.5 253.2 – 314.6
20 30 549 56 405.0 490 – 608 50.0 – 62.0 361.7 – 448.4 a
22 32 745 76 549.7 662 – 829 67.5 – 84.5 488.2 – 611.2 AD053380
3-12
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
To ensure safety at all times when operating or driving the machine, the user of the machine must
always carry out periodic maintenance. In addition, to further improve safety, the user should also carry
out periodic replacement of the parts given in the table. These parts are particularly closely connected
to safety and fire prevention.
With these parts, the material changes as time passed, or they easily wear or deteriorate. However,
it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always
be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that
they always maintain their function completely.
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 as the hoses.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same
time.
Ask your Komatsu distributor to replace the safety critical parts.
3-13
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
No. Safety critical parts for periodic replacement Q’ty Replacement interval
1 Fuel hose (Fuel tank – fuel filter) 1
2 Fuel hose (Fuel filter – P.T. pump) 1
3 Fuel hose (Fuel return – cooler tube) 1
4 Fuel hose (Cooler tube – fuel cooler in) 1
5 Fuel hose (Fuel cooler out – cooler tube) 1
6 Fuel hose (Cooler tube – fuel tank) 1
7 Steering cylinder hose 4
8 Hose of main suction tube 1
9 Outlet hoses of steering pump 2
10 Suction hoses of loader pump 2
11 Outlet hoses of loader pump 2
12 Outlet hoses of switch pump 2
13 Brake hose (Pump – accumulator charge valve) 2
14 Brake hose (Accumulator – tandem valve) 2
15 Brake hose (Accumulator – single valve) 2 Every 4000 hours
or every 2 years,
16 Brake hose (Charge valve – accumulator) 2 whichever comes
17 Brake hose (Tandem valve – front brake) 4 sooner
3-14
23. MAINTENANCE SCHEDULE CHART
INITIAL 250 HOURS SERVICE (only after the first 250 hours)
WHEN REQUIRED
3-15
23. MAINTENANCE SCHEDULE CHART
Change oil in engine oil pan, replace engine oil filter cartridge 3-45
3-16
23. MAINTENANCE SCHEDULE CHART
Lubricating 3-63
fl The interval of 2000 hours for changing the axle oil is for standard operations. If the brake is used
frequently or the brakes make a sound, change the oil after a shorter interval.
3-17
23. MAINTENANCE SCHEDULE CHART
3-18
24. SERVICE PROCEDURE
3-19
24. SERVICE PROCEDURE
CHECKING
If air cleaner clogging warning A is displayed on the CGC
monitor, clean the air cleaner element.
NOTICE
Do not clean the air cleaner element until the air cleaner
clogging warning is displayed.
If the element is cleaned frequently before the clogging warning
is displayed, the air cleaner will not be able to display its perform-
ance fully, and the cleaning efficiency will also go down.
In addition, during the cleaning operation, dirt stuck to the element
will fall inside the inner element more frequently.
3. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm2, 99.4 PSI))
from the inside of the element along its folds. Then blow with
air along the folds from the outside, and finally blow again from
the inside.
1) Remove one seal from the element each time it is cleaned.
2) Replace any outer element which has been cleaned 6 times
or used for one year. Replace the inner element at the same
time.
3) Replace both the inner and outer elements if the air cleaner
clogging warning is displayed immediately after the element
is cleaned, even if the element has not been cleaned 6 times.
4) Check for looseness of the inner element tightening nuts, AE063670
4. After cleaning the element, shine an electric light bulb from the
inside and check for small holes or thin parts on the element. If
such parts are found, replace the element.
3-20
24. SERVICE PROCEDURE
NOTICE
When cleaning the element, do not hit it or beat it against
anything.
Do not use any element if its folds or gasket or seal are
damaged.
NOTICE
Do not clean the inner element and use it again.
When replacing the outer element, replace the inner element
with a new part at the same time.
REMARK
When installing both the inner element and outer element, move
the elements lightly while tightening the nut to bring the seal rubber
at the tip of the element into tight contact with the inside of the body.
3-21
24. SERVICE PROCEDURE
¬ 17
Amount of additive (DCA4)
US gal 4.49
3-22
24. SERVICE PROCEDURE
WARNING
Coolant is flammable, so keep it away from flames.
Antifreeze is toxic. When removing the drain plug, be careful
not to get any water containing antifreeze on yourself. If it
should get into your eyes, wash your eyes with large quantities
of fresh water and see a doctor at once.
Use tap water for the coolant. If the only available water is river
water or well water, contact your Komatsu distributor for advice.
We recommend use of an antifreeze density gauge to control the
mixing proportions.
1. Stop the engine and turn corrosion resistor valve 1 to the OFF
position to close it.
4. After draining the coolant, close drain plugs 3 and 4, and fill
with tap water.
5. When the radiator is full, start the engine, run at low idling, and
operate for approx. 10 minutes to raise the water temperature to
at least 90°C (194°F).
6. Stop the engine, open drain plugs 3 and 4, and drain the water.
3-23
24. SERVICE PROCEDURE
10. Put the antifreeze, water, and additive for the coolant into a
container and mix it thoroughly. For details, see “MIXING RATE
FOR WATER, ANTIFREEZE, AND ADDITIVE”.
11. Pour in the coolant mixed in Step 10 through the water filler up
to the bottom of the water filler port.
12. To remove the air in the coolant, run the engine for 5 minutes
at low idling, then run for a further 5 minutes at high idling.
(When doing this, leave the water filler cap off.)
13. Stop the engine, wait for approx. 3 minutes, then add tap water
until the water level is near the water filler port, and tighten the
cap. Check the coolant level and add water if necessary.
1. Stop the engine and remove the cap from oil filler F.
3. The oil level should be within the range at upper area A of the
sight gauge. If the oil level is not within the range at upper area
A of the sight gauge, add engine oil through oil filler F.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
4. If the oil is above the A, remove drain plug 1 and loosen plug
2 to drain the excessive engine oil, then check the oil level
again.
The oil level can also be checked at low idling. In this case, the
oil should be within the range at bottom area B of the sight gauge.
However, the time taken for the oil level to become steady will differ
according to the idling speed and the oil temperature.
3-24
24. SERVICE PROCEDURE
Carry out this procedure if there is any sign of oil on the axle
case.
Carry out the inspection with the machine on a horizontal road
surface.
(If the road surface is at an angle, the oil level cannot be checked
correctly.)
2. Check that the oil level is near the bottom of the plug hole.
3. If the oil is not near the bottom of the plug hole, add axle oil
through the plug hole.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
3-25
24. SERVICE PROCEDURE
3-26
24. SERVICE PROCEDURE
Carry out this procedure if there is any mud or dirt stuck to the
radiator or oil cooler.
1. Remove bolt 1 and open radiator grill 2.
3. Use compressed air to clean the mud, dust, and leaves from the
radiator and oil cooler fins. Steam or water may be used instead
of compressed air.
NOTICE
If the steam nozzle is brought too near the radiator or oil cooler
fins, the fins may be damaged. Carry out the cleaning from a
reasonable distance.
4. Check the rubber hose at the same time. If the hose is found to
have cracks or to be brittle, it should be replaced with a new one.
Check for loose hose clamps and tighten them.
If there is mud or dust on the fuel cooler, clean the fuel cooler.
1. Remove cover 1 from the fuel cooler.
3-27
24. SERVICE PROCEDURE
TIP TOOTH
Replace the teeth before they wear down as far as the adapter.
1. Remove mounting pin 2 from the bucket, then remove tooth 1.
When removing pin 2, put a rod of a diameter slightly less than
the pin in contact with the pin, then hit from above, and remove
the pin from below.
Twist tooth 1 to the left when removing it.
5. After installing the tooth, remove the lifting hook with the gasket.
3-28
24. SERVICE PROCEDURE
EDGE PROTECTOR
(Edge and side edge)
1. Remove pin 2 with a bar, then slide edge protector 1 to the
front to remove it.
4. After installing the edge protector, remove the lifting hook with
the gasket.
3-29
24. SERVICE PROCEDURE
24.2.12 LUBRICATING
1. Using a grease pump, pump in grease through the grease
fittings shown by arrows.
2. After greasing, wipe off any old grease that was pushed out.
3-30
24. SERVICE PROCEDURE
If the refrigerant (gas) level is low, the cooling effect will become
poor. When the engine is running at full throttle, and the cooler is
running at high speed, look at the sight glass (inspection window)
in the receiver to check the condition of the refrigerant gas (freon
R134a) flowing in the refrigerant circuit.
‡ No bubbles in flow: Suitable
‡ Bubbles in flow: Lack of refrigerant
(bubbles pass continuously)
‡ Colorless, transparent: No refrigerant
REMARK
If there are bubbles in the sight glass, it means that the refrig-
erant level is low, so ask your refrigerant dealer to charge the cooler
with refrigerant. If the cooler is operated when the refrigerant level
is low, the compressor will be damaged.
3-31
24. SERVICE PROCEDURE
3. Use sight gauge G at the rear of the brake oil tank to check that
the oil is up to the specified level.
4. Remove the air bleed cap from the brake housing, insert one end
of a vinyl hose in the brake housing, and put the other end in a
container.
5. Depress the brake pedal and loosen air bleed screw 1 to bleed
the air. After tightening air bleed screw 1, release the brake
pedal slowly.
‡ This work should be performed by two persons. One de-
presses the brake pedal, and the other bleeds air through air
bleed screw 1.
‡ Use the left brake pedal.
‡ Supply brake oil periodically to keep the level high.
6. Repeat this operation until air bubbles stop coming out of the
hose. Then, depress the pedal fully, and tighten bleeder screw
1 while the oil is flowing out.
7. Bleed the air at all 4 locations (4 wheels). After bleeding the air,
check the oil level in the brake oil tank, and add oil if the level
is low.
‡ Put the bucket control lever at the TILT position and the lift arm
control lever at the FLOAT position, and after the cylinder
reaches the end of its stroke, keep it in that position for one
minute.
‡ Put the bucket control lever at the DUMP position and the lift arm
control lever at the RAISE position, and after cylinder reaches the
end of its stroke, keep it in that position for one minute.
3-32
24. SERVICE PROCEDURE
NOTICE
‡ Always turn the power OFF before replacing the slow blow fuse
(turn the starting switch to the OFF position).
‡ Always replace the slow blow fuse with a fuse of the same
capacity.
3-33
24. SERVICE PROCEDURE
NOTICE
If the air is not bled completely, the piston pump may be
damaged, so always carry out the air bleed operation correctly.
Before bleeding the air from the piston pump, check that the
hydraulic oil in the hydraulic tank is filled to the top of the sight
gauge. (Add oil if the level is low.)
Remove plug 1 at the top of the hydraulic tank, then connect the
pressurizing air hose.
Plug thread size: PT1/8
NOTICE Front
To prevent the oil from spurting out, pressurize the hydraulic
tank gradually.
REMARK
If all 4 plugs are loosened at the same time, oil will spurt out, so
bleed the air from 1 plug at a time.
3. When oil flows out from the plug hole, the air has been com-
pletely bled, so stop pressurization of the hydraulic tank, and
tighten plug 1.
There are plugs for each pump, so loosen all four plugs.
3-34
24. SERVICE PROCEDURE
NOTICE
To prevent the oil from spurting out, pressurize the hydraulic Front
tank gradually.
3. When oil flows out from the plug hole of each pump, the air has
been completely bled, so stop pressurization of the hydraulic
tank and tighten plug 3.
4. Check the hydraulic oil level, and add oil if the oil level is low.
5. Remove the pressurizing air hose from the hydraulic tank and
install plug 1.
3-35
24. SERVICE PROCEDURE
NOTICE
When bleeding the air, 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.
2. Start the engine, run at low idling for approx. 5 minutes, then
check that there is no oil leakage from any place.
3. Run the engine at low idling, and extend and retract the steering,
bucket, and lift arm cylinders 4 - 5 times. Be careful not to
operate the cylinder to the end of its stroke (stop approx. 100 mm
(3.9 in) before the end of the stroke).
4. Next, operate the steering, bucket, and lift arm cylinders to the
end of their stroke 3 – 4 times, then stop the engine.
6. Check that the hydraulic oil is at the specified level. For details,
see “24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL”.
7. Next, increase the engine speed (1500 rpm) and repeat the
procedure in Steps 4 and 5 to bleed the air.
Continue this operation until no more air comes out from plug
1.
9. Check that the hydraulic oil is at the specified level. For details,
see “24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL”.
3-36
24. SERVICE PROCEDURE
SELECTION OF TIRES
WARNING
It is necessary to select tires that match the conditions of use
of the machine and the weight of the attachments installed.
Always use the tires specified by Komatsu and maintain the
tires at the specified inflation pressure.
Maximum
Tire size Remarks
load
95,300 kg
55.5/80-57-68PR(L5) (standard)
(210,137 lb)
Front wheel
95,000 kg
65/65-57-62PR(L5) (if equipped)
(209,475 lb)
95,300 kg
55.5/80-57-68PR(L5) (standard)
(210,137 lb)
Rear wheel
95,000 kg
65/65-57-62PR(L5) (if equipped)
(209,475 lb)
3-37
24. SERVICE PROCEDURE
Check
Use a tire pressure gauge to measure the tire inflation pressure
when the tire is cold before starting operations.
Inflating tires
Adjust the tires to the appropriate inflation pressure.
When pumping up the tires, use an air chuck that can be fixed
to the air valve of the tire as shown in the diagram. When pumping
up the tire, do not stand in front of the tire; carry out the operation
from beside the tread.
See the table below for the appropriate inflation pressure.
NOTICE
The appropriate tire inflation pressure differs according to the
type of work. For details, see “12.15 HANDLING TIRES”.
3-38
24. SERVICE PROCEDURE
3-39
24. SERVICE PROCEDURE
3-40
24. SERVICE PROCEDURE
1. Lower the bucket horizontally to the ground and stop the engine.
Wait for 5 minutes, then check sight gauge G. The oil level
should be near the top of sight gauge G.
NOTICE
Do not add oil above the H line. If oil has been added to above
the H level, stop the engine and wait for the hydraulic oil to cool
down, then drain the excess oil from the drain plug.
If the oil is above the H level, it will damage the hydraulic circuit
or cause the oil to spurt out.
2. If the oil is not up to the top of the sight gauge, open the
inspection cover at the top of the step and add oil through oil
filler port F.
When adding oil, check the oil level with dipstick 1.
The oil should be near the H mark on the dipstick.
3-41
24. SERVICE PROCEDURE
1. Open air conditioner FRESH filter cover 1 at the rear of the cab.
2. Remove wing nut 2, take out filter element 3, and clean it.
3. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm2, 99.4 PSI))
from the inside of the element along its folds. Then blow with
air along the folds from the outside, and finally blow again from
the inside.
REMARK
When assembling the element again, install so that the arrow at
the top of the element faces the inside of the cab.
3-42
24. SERVICE PROCEDURE
NOTICE
When adding distilled water in cold weather, add it before
starting operations in the morning to prevent the electrolyte from
freezing.
1. Use a wet cloth to clean the area around the electrolyte level
lines and check that the electrolyte level is between the UPPER
LEVEL (U.L) and LOWER LEVEL (L.L) lines.
If the battery is wiped with a dry cloth, static electricity may
cause a fire or explosion.
2. If the electrolyte level is below the midway point between the U.L
and L.L lines, remove cap and add distilled water to the U.L line.
REMARK
If distilled water is added to above the U.L line, use a pipette to
lower the level to the U.L line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), then flush it away with a large
amount of water or consult your Komatsu distributor or battery
maker.
3-43
24. SERVICE PROCEDURE
1. Remove cap at the top of the battery, look through the water filler
port, and check the electrolyte surface. If the electrolyte does not
reach the sleeve, add distilled water so that the level reaches the
bottom of the sleeve (UPPER LEVEL line) without fail.
Use the diagram below for reference, and check if the electrolyte
reaches the bottom of the sleeve.
REMARK
If distilled water is added to above the bottom of the sleeve, use
a pipette to lower the level to the bottom of the sleeve. Neutralize
the removed fluid with baking soda (sodium bicarbonate), then flush
it away with a large amount of water or consult your Komatsu
distributor or battery maker.
3-44
24. SERVICE PROCEDURE
1. Open the engine side cover at the left side of the machine, then
open engine oil filler F.
2. Set the container to catch the oil immediately under drain plug
P on the left side of the machine.
6. Open the cover at the front face of the center fuel tank, then set
the container to catch the oil immediately under drain plug 1.
11. Clean the filter holder, fill the new filter cartridge with clean
engine oil, coat the seal surface and thread of the filter cartridge
with engine oil, then install the filter cartridge to the filter oil
holder.
12. When installing, tighten until the packing surface contacts the
filter holder, then tighten a further 3/4-1 turn.
3-45
24. SERVICE PROCEDURE
13. After replacing the filter cartridge, add engine oil through oil
filler port F so that the oil level is between the H and L marks
on dipstick G.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
14. Run the engine at idling for a short time, and check that there is
no leakage of oil from the filter or drain plug.
15. Stop the engine, wait for approx. 5 minutes, and check again that
the oil level is between the H and L marks on dipstick G.
For details, see “12.1.2 CHECK BEFORE STARTING”.
1. Open the cover at the front of the center fuel tank, then set the
container under the fuel filter cartridge to catch the oil.
3. Loosen the plug at the bottom of the filter cartridge and drain the
fuel from filter cartridge 2.
3-46
24. SERVICE PROCEDURE
6. Clean the seal surface of the filter head, then install the supplied
seal ring to the new filter.
7. Fill the new filter cartridge with clean fuel, coat the packing
surface thinly with clean engine oil, then install to the filter head.
WARNING
The engine will start, so check carefully that the area around the
engine is safe before cranking.
9. After replacing the filter cartridge, turn the starting switch to the
START position and start the engine. Run the engine and check
for any leakage from the filter seal surface. If any leakage is
found, check the tightening of the filter cartridge.
If there is still fuel leakage, repeat Steps 2 and 3 to remove the
filter cartridge, then check the packing surface for damage or
foreign material caught in the surface.
If any damage or foreign material is found in the packing, replace
the filter cartridge with a new filter cartridge, then repeat Steps
4 to 8 to install the new filter cartridge.
3-47
24. SERVICE PROCEDURE
There is an expiry date for the test kit, so stock a suitable number
to match the frequency of use.
NOTICE
If the density of the cooling water additive is too low, it will
cause pitting of the liner and corrosion of the system. If the density
is too high, the cause is leakage from the water pump seal.
3-48
24. SERVICE PROCEDURE
NOTICE
Replace the corrosion resistor cartridge only when necessary.
For details, see “24.6.5 CHECK, ADJUST DENSITY OF COOLING
WATER ADDITIVE”.
1. Open the engine side cover located on the right of the engine
hood.
3. Using the filter wrench, turn cartridge 2 to the left to remove it.
4. Clean the seal surface of the filter holder and the area around the
filter holder.
If there is any cartridge seal remaining on the filter holder,
remove it.
5. Coat the seal surface of the new cartridge with engine oil, and
install it to the filter holder.
6. When installing, bring the gasket into contact with the seal
surface of the filter holder, then tighten approx. 1/2 - 3/4 turns.
8. Start the engine and check that there is no leakage of water from
the cartridge seal surface.
3. Adjust the belt tension to the specified value. Turn rod 3 in the
direction of the arrow to increase the tension.
If the fan belt does not reach the specified tension even when the
rod is adjusted, please contact your Komatsu distributor for
checking and adjusting.
3-49
24. SERVICE PROCEDURE
REMARK
When rotating the crankshaft, use a barring tool.
3-50
24. SERVICE PROCEDURE
ADJUSTING
1. Loosen bolt 1.
2. Loosen locknut 2.
5. Tighten bolt 1.
6. Check each pulley for damage and wear of the V-groove, and
check the V-belt for wear. Be particularly careful to check that the
V-belt does not contact the bottom of the V-groove.
3-51
24. SERVICE PROCEDURE
2. If any stud bolt is broken, replace all the stud bolts for that wheel.
2. Clean with 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.
2. Check all parts of the frame and lift arm for damage.
In particular, check the colored part in the diagram, and repair
if any cracks or other damage are found.
For details of the method of repair, please contact your Komatsu
distributor.
3-52
24. SERVICE PROCEDURE
NOTICE
‡ Do not remove follower plate 2. If follower plate 2 is not used,
pump 3 will be unable to suck up grease even if there is still
a large quantity of grease in the can.
‡ Always use the applicable follower plate regardless of whether
a pail can is used or not.
3-53
24. SERVICE PROCEDURE
2. Set the container to catch the oil under the filter case.
4. Remove drain plug P, then loosen plug 3 slowly and drain the
oil.
5. After draining the oil, tighten plug 3, then install drain plug P.
3-54
24. SERVICE PROCEDURE
8. Check that there is no foreign material inside the filter case, then
clean the inside of the case.
10. Hold down the cover and tighten the mounting bolts uniformly.
11. Run the engine at idling for a short time, then check that the oil
is up to the specified level. For details, see ”24.2.3 CHECK
TRANSMISSION OIL LEVEL, ADD OIL”.
3-55
24. SERVICE PROCEDURE
1. Set the container directly under the brake oil drain valve to catch
the oil.
5. After draining the oil, tighten plugs 5 and 8, then install drain
plugs 4 and 7.
3-56
24. SERVICE PROCEDURE
8. Check that there is no foreign matter inside the tank, then clean
the inside of the tank.
10. Hold down cover 0 and tighten the mounting bolts uniformly.
11. Remove the mounting bolts of cover D at the top of the brake
oil cooling tank, then remove the cover.
When doing this, hold down the cover while removing the bolts
to prevent the cover from flying off under the force of spring E.
12. Remove spring E and bypass valve F, then take out element G.
13. Check that there is no foreign matter inside the tank, then clean
the inside of the tank.
14. Install a new element, then set bypass valve F, spring E, and
cover D to the brake oil cooling tank.
When assembling, replace the cover O-ring if it is damaged or
deteriorated.
15. Hold down cover D and tighten the mounting bolts uniformly.
16. Add engine oil through oil fillers F to the specified level, then
install plugs 2 and 3 in the center of the filter cover.
18. Idle the engine for a short time, then check that the oil is at the
specified level. For details, see ”12.1.2 CHECK BEFORE START-
ING”.
3-57
24. SERVICE PROCEDURE
2. After greasing, wipe off any old grease that is pushed out.
3-58
24. SERVICE PROCEDURE
2. After draining the oil, tighten plug 2, then install drain plug 1.
3. Drain the oil from the filter case. For details, see “24.7.1 RE-
PLACE TRANSMISSION FILTER ELEMENT”.
After draining the oil, close the drain valve and install the drain
plug.
3-59
24. SERVICE PROCEDURE
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
8. After filling with oil, check that the oil is at the specified level. For
details, see “24.2.3 CHECK TRANSMISSION OIL LEVEL, ADD
OIL”.
9. Check that there is no oil leakage from the transmission case and
filter.
3-60
24. SERVICE PROCEDURE
1. Open inspection cover 1 at the left side of the machine, and set
the container to catch the oil under the engine oil bypass filter.
3-61
24. SERVICE PROCEDURE
7. Clean all parts and the seal surface with a clean cloth.
10. Install turbine case 9, cone washer 8, and nut 7 to rotor turbine
B. Tighten nut 7 fully by hand.
NOTICE
Tighten nut 7 by hand. Do not tighten it with a wrench.
11. Be careful not to damage the brush portion of the filter and
install turbine assembly 6.
If turbine assembly 6 is correctly installed to the filter base,
turbine assembly 6 can move freely in the direction of rotation.
16. Check that the oil is up to the specified level. For details, see
“12.1.2 CHECK BEFORE STARTING”.
3-62
24. SERVICE PROCEDURE
24.8.4 LUBRICATING
1. Using a grease pump, pump in grease through the grease
fittings marked by the arrows.
2. After greasing, wipe off any old grease that is pushed out.
3-63
24. SERVICE PROCEDURE
3-64
24. SERVICE PROCEDURE
6. After draining the oil, close drain valve 2, then tighten drain
plug 3.
3-65
24. SERVICE PROCEDURE
9. Check that there is no foreign material inside the tank, then clean
it.
10. Install a new element, then set bypass valve 7, spring 6, and
cover 4 to the tank.
Replace O-ring 9 of the cover with a new part.
11. Hold down the cover and tighten the mounting bolts uniformly.
12. Add engine oil through oil filler port F to the specified level, then
install the cap and plug 1 of the filter case.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
13. Bleed the air from the piston pump and the hydraulic system.
For details, see “24.2.17 BLEEDING AIR FROM HYDRAULIC
TANK”.
NOTICE
Be sure to bleed the air completely. If the air is not completely
bled, the piston pump and cylinders may be broken.
15. Lower the bucket horizontally to the ground and stop the engine.
16. Check that the hydraulic oil is at the specified level. For details,
see “24.5.1 CHECK HYDRAULIC TANK OIL LEVEL, ADD OIL”.
17. Check that there is no leakage of oil from the filter cover mount.
3-66
24. SERVICE PROCEDURE
4. Remove any dirt from strainer 4, then wash in clean diesel oil
or flushing oil.
If strainer 4 is broken, replace it with a new part.
6. Install holder 3.
Replace O-ring 6 of the holder with a new part.
3-67
24. SERVICE PROCEDURE
2. Remove the snap ring from breather 1, then remove the breather
cap.
3. Replace the filter element with a new part, then install the
breather cap and snap ring.
REMARK
It is possible to replace the element with the breather installed
in the tank. However, if the breather is removed, do not wrap the
taper thread of the breather with seal tape when assembling again,
and be careful not to tighten too much.
2. Take out the strainer, remove the dirt stuck to the strainer, then
wash the strainer with clean diesel fuel or flushing oil.
If the strainer is broken, replace it with a new part.
4. Operate the bucket control lever to the TILT position and the lift
arm control lever to the FLOAT position, and when the cylinder
reaches the end of its stroke, hold it there for one minute.
5. Operate the bucket control lever to the DUMP position and the
lift arm control lever to the RAISE position, and 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 “24.2.15
BLEEDING AIR FROM PPC CIRCUIT”.
3-68
24. SERVICE PROCEDURE
1. Remove front oil filler plug 1, then remove drain plug 2 and
drain the oil.
2. Remove rear oil filler plug 1, then remove drain plug 2 and
drain the oil.
3. Stop the machine so that drain plug 3 of the final drive is at the
bottom. Remove oil filler plug 4 and drain plug 3, then insert
the tube of the supplied tool in the hole of plug 3 and drain the
oil.
4. After draining the oil, clean drain plugs 2 and 3, then install
them.
3-69
24. SERVICE PROCEDURE
5. Add the specified amount of oil through oil filler ports 1 and 4
of the axle housing and left and right final drives.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
6. After adding oil, check at level plug 1 that the oil is at the
specified level. For details, see “24.2.4 CHECK AXLE OIL LEVEL,
ADD OIL”.
REMARK
For operations where the brake is used frequently, change the
axle oil at shorter intervals.
3-70
24. SERVICE PROCEDURE
1. Set the container directly under the brake oil tank to catch the oil.
4. After draining the oil, tighten plugs 5 and 7, then install drain
plugs 4 and 6.
6. Loosen drain plugs 8 and 9, and drain the oil from the 4 wheels
(front, rear, left, and right).
For details of the oil to use, see “20. USE OF FUEL COOLANT
AND LUBRICANTS TO AMBIENT TEMPERATURE”.
11. Start the engine and bleed the air from the circuit. For details,
see “24.2.14 BLEEDING AIR FROM BRAKE HYDRAULIC CIR-
CUIT”.
12. Idle the engine for a short time, then check that the oil is at the
specified level. For details, see “12.1.2 CHECK BEFORE START-
ING”.
3-71
24. SERVICE PROCEDURE
2. Remove the snap ring from breather 1, then remove the breather
cap.
3. Replace the filter element with a new part, then install the
breather cap and snap ring.
REMARK
It is possible to replace the element with the breather installed
in the tank. However, if the breather is removed, do not wrap the
taper thread of the breather with seal tape when assembling again,
and be careful not to tighten too much.
3-72
24. SERVICE PROCEDURE
Checking
1. Stop the machine on level ground and apply the parking brake.
3. Leave the work equipment in this position, and stop the engine.
4. Confirm that it is safe around the machine, then set the lift arm
at FLOAT and lower the work equipment to a position 1 m from
the ground.
Carry out the checks within five 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.
3-73
24. SERVICE PROCEDURE
5. Add gear oil through the top plug hole until it flows out from the
plug hole.
1. Lift cylinder pin (bottom end) (2 places) (5.4 ¬ (1.49 US gal) each)
2. Lift cylinder pin (rod end) (2 places) (4.8 ¬ (1.27 US gal) each)
3. Bucket cylinder pin (bottom end) (2 places) (1.8 ¬ (0.48 US gal) each)
4. Bucket cylinder pin (rod end) (2 places) (1.7 ¬ (0.45 US gal) each)
5. Bucket link pin (bellcrank end) (2 places) (1.9 ¬ (0.50 US gal) each)
6. Bucket link pin (bucket end) (2 places) (2.0 ¬ (0.53 US gal) each)
7. Bellcrank pin (2 places) (5.6 ¬ (1.48 US gal) each)
8. Lift arm hinge pin (2 places) (11.2 ¬ (2.96 US gal) each)
9. Bucket hinge pin (2 places) (5.6 ¬ (1.48 US gal) each)
3-74
24. SERVICE PROCEDURE
NOTICE
To prevent problems caused by water entering the engine
openings and electric system, be careful not to direct steam at such
parts.
2. After greasing, wipe off all the grease that was pushed out.
3-75
24. SERVICE PROCEDURE
3-76
SPECIFICATIONS
4-1
25. SPECIFICATIONS
WA1200-3
Tire size
Item
55.5/80-57-68 PR 65/65-57-62PR
Operating weight (including one operator: 75 kg (165 lb)) 205,200 kg (452,466 lb) 210,400 (463,932 lb)
Normal load 36,000 kg (79,380 lb)
Bucket capacity 20 m3 (25.9 cy.yd)
Engine model Cummins QSK60
Flywheel horsepower 1,163kW (1,560 HP)/1,900 rpm
(Rock: 18,210 mm (59 ft 9 in))
A Overall length Tip of bucket (tip of teeth) 17,680 mm (58 ft)
(Limestone: 18,175 mm 59 ft 8 in))
B Overall height 6,865 mm (22 ft 6 in) 6,930 (22 ft 9 in)
C Max. dimension when shaking bucket 11,865 mm (38 ft 11 in) 11,930 (39 ft 2 in)
D Overall width 5,710 mm (18 ft 9 in) 5,970 (19 ft 7 in)
E Min. ground clearance 650 mm (2 ft 2 in) 715 (2 ft 4 pin)
F Bucket width 6,550 mm (21 ft 6 in)
Rock: 6,285 mm (20 ft 7 in) 6,350 mm (20 ft 10 in)
(6,735 mm (22 ft 1 in)) (6,800 mm (22 ft 4 in))
G Clearance Tip of teeth (tip of bucket)
Limestone:6,325 mm (20 ft 9 in) 6,390 mm (21 ft)
(6,735mm (22 ft 1 in)) (6,800 mm (22 ft 4 in))
Rock: 2,970 mm (9 ft 8 in) 2,905 mm (9 ft 6 in)
(2,665 mm (8 ft 9 in)) (2,600 mm (8 ft 6 in))
H Reach Tip of bucket (tip of teeth)
Limestone:2,955 mm (9 ft 8 in) 2,890 mm (9 ft 6 in)
(2,665 mm (8 ft 9 in)) (2,600 mm (8 ft 6 in))
I Dump angle 45°
Outside of machine 14,330 mm (47 ft)
Min. turning radius
Center of outside tire 12,015 mm (39 ft 5 in)
1st 6.3 km/h (3.9 MPH) 6.5 (4.0 MPH)
Forward 2nd 11.5 km/h (7.1 MPH) 11.9 (7.4 MPH)
3rd 19.8 km/h (12.3 MPH) 20.4 (12.7 MPH)
Travel speed (low speed/highspeed)
1st 7.4 km/h (4.6 MPH) 7.7 (4.8 MPH)
Reverse 2nd 13.4 km/h (8.3 MPH) 13.9 (8.6 MPH)
3rd 22.6 km/h (14.0 MPH) 23.2 (14.4 MPH)
4-2
25. SPECIFICATIONS
4-3
MEMO
4-4
OPTIONS, ATTACHMENTS
¤ WARNING
Before reading this section, be sure that you have read and
understood the SAFETY section.
5-1
26. SELECTION BUCKETS AND TIRES
Select the most suitable bucket and tires for the type of work and the ground conditions on the
jobsite.
The above explanation covers the most commonly used combinations. For details of combinations
of other attachments, such as the high-lift bucket and bucket with spade nose zipper lip, and 53.5/85-
57 tires, please contact your Komatsu distributor.
The displayed travel speed changes according to the tire size, so when installing optional tires, please
contact your Komatsu distributor.
On jobsites where there are boulders or sharp rocks, install tire protectors (mesh chain).
Check the chain for cuts or sagging before starting operation.
Be careful not to let the tires and chain slip during operation.
5-2
27. STARTING IN COLD AREAS
In cold weather, when it is necessary to warm up the oil and water, do as follows to warm up all
parts before starting the engine and operating the machine.
‡ The electric heater keeps the following coolant and lubricating oil warm.
1. Engine oil
2. Hydraulic oil
3. Transmission oil
1. When using this electric heater, it is necessary to provide the following external power source.
For details, see “27.1.3 ESTABLISHING POWER SUPPLY”.
‡ Type of electricity: Single phase AC
‡ Voltage: 230 volts
‡ Power supply: 10.5 kilovolt ampere (kVA) or above
2. It is necessary to make locally the cable used to bring the electricity above to the power input installed
to the machine from the external power source.
For details of the manufacturing procedure, see Step 3.
5-3
27. STARTING IN COLD AREAS
Manufacturing procedure
1. For the wiring, purchase locally a three-core type 2 EP rubber
insulated chloroprene sheath cabtire cable, using the specifica-
tions below for reference Fig. 2.
‡ Nominal cross-sectional area of one core should be 14 m2.
‡ For the voltage resistance function, it should be able to with-
stand 3000 V for 1 minute.
‡ Make the length less than 30 m to prevent any drop in voltage.
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27. STARTING IN COLD AREAS
2. Connect the chassis input side connector (shipped as individual part) 426-06-11630 (connector) to the
tip of the cable.
There are three contacts in the connector, and each has a symbol, so connect the three core wires
of the cable as shown in the table below.
CAUTION
‡ Solder the contact and core wire to connect them.
‡ To prevent short circuits caused by contact between the conductors, insulate the soldered parts
with rubber tube or tape.
‡ Always use connector 426-06-11630.
If another connector is used, it cannot be connected with the external power source input
receptacle.
3. Modify the other end of the cable so that it can be connected to the power supply in Fig. 1.
After completing the modification of the connection, the external power source input cable is
completed.
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27. STARTING IN COLD AREAS
Note: When setting up the power supply, follow all related laws and regulations in that country and
use an authorized contractor.
This completes the operations for setting up the external power supply.
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MEMO
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WA1200-3 WHEEL LOADER
©2004 7